Hexagonal Jelly-Roll Battery Cell for Higher Pack Density

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Solution Overview

Problem

Existing battery cell configurations in vehicle battery packs fail to maximize volumetric efficiency and cell density, leading to suboptimal packaging and increased footprint, which limits the number of cells that can be used in a given space.

Innovation Solution

The use of hexagonally shaped battery cells with a jelly roll configuration, featuring non-uniform thickness layers and aligned current collector tabs, is proposed to maximize packing efficiency by allowing closer side-by-side arrangement of cells within a polygonally shaped case, thereby minimizing gaps and optimizing space utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If conventional battery cell configurations are used, then manufacturing and assembly are simpler, but volumetric efficiency and cell density are not maximized

Engineering Contradiction:

Improvevolumetric efficiencyVSAvoidcell configuration complexity

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The patent employs asymmetric hexagonal prism geometry for battery cells, where the cross-sectional shape is hexagonal rather than circular. This asymmetric polygonal configuration allows cells to be arranged in tightly packed arrays that maximize volumetric efficiency within the battery pack envelope, eliminating wasted space between cells while maintaining structural integrity

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent transitions from traditional cylindrical or prismatic cell geometries to hexagonal prism geometry, adding dimensional optimization for packing efficiency. The hexagonal cross-section enables superior spatial arrangement in multiple dimensions, allowing closer side-by-side placement of cells and maximizing the number of cells that can be accommodated within a given volume

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Area of stationary object

If conventional battery cell shapes are used, then packaging is easier, but battery pack footprint is increased

Engineering Contradiction:

Improvebattery pack footprintVSAvoidpackaging complexity

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The hexagonal prism cell geometry with flat sides enables optimized packing arrangements that minimize the overall battery pack footprint. The asymmetric hexagonal shape allows cells to be arranged in closely packed configurations that reduce wasted space and minimize the envelope volume required, thereby reducing the battery pack footprint compared to conventional circular or rectangular cell arrangements

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The battery pack is segmented into multiple hexagonal cells arranged in a systematic pattern. This segmentation approach allows the total battery capacity to be distributed across many smaller units that can be tightly packed together, optimizing the use of available space and minimizing the overall footprint while maintaining ease of assembly through standardized cell modules

Inventive Principle:

Principle #1Segmentation

3Power

If fewer battery cells are used, then packaging is simpler, but power output is limited

Engineering Contradiction:

Improvepower outputVSAvoidnumber of cells

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The battery system is divided into multiple individual hexagonal cells, each contributing to the total power output. By segmenting the battery into numerous smaller cells that can be tightly packed, the system achieves higher total power capacity within the same volume compared to fewer larger cells, as the hexagonal geometry maximizes the number of cells that can be accommodated

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The battery pack functions as a composite system of multiple hexagonal cells working together to deliver high power output. The hexagonal cell design enables superior spatial utilization, allowing a greater number of active cells to be integrated into the pack, thereby increasing total power capacity without proportionally increasing volume or weight

Inventive Principle:

Principle #40Composite materials

4Volume of moving object

If non-uniform thickness layers are used in jelly roll, then space utilization is optimized, but manufacturing precision requirements increase

Engineering Contradiction:

Improvespace utilizationVSAvoidlayer thickness precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The jelly roll structure incorporates electrodes with non-uniform thickness distribution, where local variations in thickness are optimized to match the hexagonal geometry. Thicker electrode sections are positioned strategically within the hexagonal prism to maximize active material content and space utilization, while thinner sections accommodate the geometric constraints, thereby optimizing volumetric energy density

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250023088A1Hexagonal battery cell with wound jelly roll

Publication Date: 2025.01.16 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A hexagonal battery cell. The battery cell may include a wound jelly roll within a hexagonally shaped case. The jelly roll may include a separator layer sandwiched between a cathode layer and an anode layer, with the separator, cathode, and anode layers wound together relative to a central axis. The hexagonally shaped case may surround a perimeter of the jelly roll.