Octagonal Planar Web Cushioning for Uniform Battery Cell Pressure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cushioning materials for battery cells, particularly in solid-state batteries, fail to maintain uniform pressure and pressure uniformity during charge-discharge cycles, leading to potential interface failure and reduced battery life.
Innovation Solution
A planar web composed of hollow octagonal tubes with specific geometric dimensions and bonding configurations is used to provide a stable Compression Force Deflection (CFD) plateau, ensuring uniform stress distribution across a wide range of compression levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cushioning materials are used for battery cells, then the battery module can be assembled, but the materials fail to maintain uniform pressure during charge-discharge cycles leading to interface failure
Solution Approach 1:
The patent applies parameter changes by carefully controlling the geometric parameters of the hollow tube structure including the octagonal cross-section shape, wall thickness-to-height ratio (T/H between 0.02 and 0.25), and interior angles (X between 100 and 140 degrees). These parameter optimizations enable the structure to maintain stable compressive stress characteristics across charge-discharge cycles while preserving interface integrity between electrolyte and electrodes
2Duration of action of stationary object
If existing cushioning materials are used, then the battery module structure is simple, but the pressure distribution becomes non-uniform causing reduced battery life
Solution Approach 1:
The patent applies segmentation by dividing the cushioning material into an array of discrete hollow tubes with octagonal cross-sections. Each tube acts as an independent compression element that distributes stress uniformly across the contact surface. The segmented structure prevents stress concentration points that would otherwise lead to interface failure and reduced battery life
Solution Approach 2:
The patent employs composite material principles by creating a planar web structure that combines multiple hollow tubes into an integrated cushioning system. The composite arrangement of tubes bonded together forms a unified structure that maintains both structural integrity and uniform pressure distribution characteristics essential for extending battery operational life
3Reliability
If traditional cushioning materials are used, then the design is simple, but they cannot maintain consistent compressive stress across multiple cycles
Solution Approach 1:
The patent utilizes parameter changes by optimizing the hollow tube geometry including the octagonal cross-section, wall thickness ratios (T/H between 0.02 and 0.25), and interior angles (100-140 degrees). These specific parameter ranges enable the structure to exhibit stable compressive stress characteristics across multiple charge-discharge cycles while maintaining manufacturability
Solution Approach 2:
The patent applies flexible shell principles by using hollow tubes with thin walls relative to their height (T/H ratio between 0.02 and 0.25). These thin-walled flexible structures can deform elastically under compression and recover, maintaining consistent mechanical properties across cycles. The flexible nature allows the tubes to accommodate volume changes during charge-discharge while preserving contact pressure
Data Source
AI summary
A planar web includes a plurality of hollow tubes. Each hollow tube has an octagonal cross section including eight walls. The eight walls include a first surface wall and a second surface wall where each surface wall has a length A; two side walls perpendicular to the surface walls were each side wall having a length B; and four connecting walls. 0.2≤B/A≤1. Adjacent side walls of adjacent hollow tubes are bonded together to form the planar web having a first planar surface comprising the first surface walls and a second planar surface comprising the second surface walls. Each connecting wall independently connects one of the surface walls to one of the side walls. Each wall has a thickness T and each hollow tube has a height H measured from the first surface wall to the second surface wall. 0.02≤T/H≤0.25.