Multiple Jelly Rolls in Single Pouch Battery
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Solution Overview
Problem
Conventional lithium-polymer batteries face challenges in packaging efficiency, capacity, form factor, and manufacturing cost due to the limitations of single jelly roll pouches in portable electronic devices.
Innovation Solution
A battery cell design featuring multiple jelly rolls enclosed in a single pouch, with conductive tabs for electrical connections in series, parallel, or series-and-parallel configurations, allowing for asymmetric designs and varying thicknesses and lengths to optimize space usage and capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple pouches are placed side-by-side to increase capacity, then battery capacity increases, but packaging efficiency decreases and device space consumption increases
Solution Approach 1:
Multiple jelly rolls that would traditionally require separate pouches are merged into a single shared pouch, reducing the total pouch count and associated packaging materials. This combining approach maintains full battery capacity while improving packaging efficiency and reducing device space consumption by eliminating redundant pouch structures.
Solution Approach 2:
A single pouch structure is designed to serve multiple functions by accommodating and protecting multiple jelly rolls simultaneously. The pouch acts as a universal container that provides mechanical support, electrical isolation, and sealing for all jelly rolls, replacing the need for individual pouches for each jelly roll.
2Quantity of substance
If jelly rolls are placed side-by-side in a pouch, then capacity increases, but width requirements increase
Solution Approach 1:
Instead of placing jelly rolls side-by-side in the horizontal plane (increasing width), the invention stacks jelly rolls vertically within the pouch along the thickness dimension. This dimensional transition allows multiple jelly rolls to be accommodated without increasing pouch width, thereby maintaining device form factor while increasing capacity.
3Ease of manufacture
If conventional single jelly roll pouches are used, then manufacturing is simple, but packaging efficiency is limited
Solution Approach 1:
Multiple jelly rolls are combined within a single pouch, reducing the total number of pouches required and associated packaging materials. This merging approach improves packaging efficiency by better utilizing the available volume while maintaining manufacturing simplicity through standardized pouch fabrication processes.
Data Source
AI summary
The disclosed embodiments provide a battery cell which includes a set of jelly rolls enclosed in a pouch. Each jelly roll includes layers which are wound together, including a cathode with an active coating, a separator, and an anode with an active coating. The battery cell also includes a first set of conductive tabs and a second set of conductive tabs. Each of the first set of conductive tabs is coupled to the cathode of one of the jelly rolls, and each of the second set of conductive tabs is coupled to the anode of one of the jelly rolls. At least one of the first set and one of the second set of conductive tabs extend through seals in the pouch to provide terminals for the battery cell.