Multi-Cavity Battery Shell Layout for Higher Energy Density

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Solution Overview

Problem

Current battery technologies face challenges in achieving high energy density due to low space utilization and gaps between electrode assemblies, leading to reduced performance and safety risks.

Innovation Solution

The design incorporates a shell assembly with multiple accommodating cavities sharing partition walls, each equipped with output assemblies and electrode assemblies, allowing for efficient space utilization and electrical connections, thereby enhancing energy density and reducing the risk of electrolyte leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If traditional battery structures with separate compartments are used, then manufacturing simplicity is maintained, but space utilization is low and energy density is reduced

Engineering Contradiction:

Improveenergy densityVSAvoidstructure complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent merges multiple compartment walls into shared partition walls that simultaneously serve as boundaries for adjacent accommodating cavities. This merging approach eliminates redundant structures, increases space utilization within the shell assembly, and improves energy density without significantly increasing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The partition walls are designed to serve multiple functions: they act as structural dividers between accommodating cavities, provide mounting surfaces for output assemblies, and contribute to the overall structural integrity of the battery. This multi-functionality reduces the need for additional components and enhances space efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Quantity of substance

If more accommodating cavities are added to increase energy density, then space utilization improves, but the risk of electrolyte leakage between cavities increases

Engineering Contradiction:

Improveenergy densityVSAvoidelectrolyte leakage risk

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

Adjacent accommodating cavities share common partition walls that are integrally formed or tightly joined, eliminating gaps between separate compartments. This merged structure prevents electrolyte leakage while maintaining high space utilization and energy density.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent converts the potential harm of multiple cavities (leakage risk) into a benefit by using the shared partition walls as both structural elements and sealing barriers. The same walls that enable space-efficient multi-cavity design also serve as reliable leakage prevention mechanisms.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If separate compartment walls are used for each accommodating cavity, then manufacturing simplicity is maintained, but space utilization and energy density are reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidenergy density

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent combines multiple individual compartment walls into shared partition walls that serve adjacent cavities simultaneously. This merging reduces the total number of manufacturing steps and components while increasing the effective space for electrode assemblies, thereby improving energy density without significantly complicating manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

4Quantity of substance

If shared partition walls are used between adjacent accommodating cavities, then space utilization and energy density are improved, but manufacturing complexity increases

Engineering Contradiction:

Improveenergy densityVSAvoidmanufacturing complexity

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The shell assembly is segmented into multiple accommodating cavities that share partition walls. This segmentation approach allows for modular assembly where cavities can be manufactured and assembled in a systematic manner, reducing the overall manufacturing complexity despite the increased structural efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The shared partition walls perform multiple functions including structural division, electrolyte containment, and support for output assemblies. This multi-functionality reduces the total number of components needed, simplifying the overall manufacturing process while maintaining high energy density.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20240372178A1Battery, electrical device, method for manufacturing battery, and device for manufacturing battery

Publication Date: 2024.11.07 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

A battery includes electrode assemblies and a shell assembly. The electrode assembly comprises two tabs. A plurality of accommodating cavities are formed inside the shell assembly, and accommodates at least one of the electrode assemblies, and adjacent cavities share a partition wall that partitions the two adjacent accommodating cavities. The shell assembly includes a plurality of output assemblies, each of the cavities is correspondingly provided with one of the output assemblies which each include two output electrodes respectively configured to be electrically connected to the two tabs of the electrode assembly in the corresponding cavity.