Pouch Battery Case Overlap Design for Breakage Prevention
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Solution Overview
Problem
The existing manufacturing processes for pouch-type batteries face challenges such as breakage of the battery case during assembly, difficulty in forming receiving parts with sufficient depth, and increased manufacturing costs due to the need for additional guide units and potential air introduction, which reduces the battery's service life.
Innovation Solution
A pouch-type battery design featuring a one-unit sheet-type battery case with symmetrical receiving parts that overlap and are bent along a specific line, incorporating bent depression parts to enhance structural integrity and simplify assembly, allowing for deeper receiving parts and reduced atmospheric exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the aluminum laminate sheet is compressed to form receiving parts, then the receiving parts can be formed in the battery case, but the aluminum laminate sheet may break during compression
Solution Approach 1:
The patent applies preliminary action by forming guide grooves and bent depression parts in the battery case before receiving and compressing the electrode assembly. These pre-formed structural features guide the compression process and distribute stress, preventing laminate sheet breakage while enabling proper receiving part formation.
Solution Approach 2:
The patent introduces bent depression parts and guide grooves as intermediary structural elements between the compression force and the laminate sheet. These intermediaries mediate the compression process by providing stress distribution paths and geometric guidance, reducing direct stress concentration on the thin laminate sheet.
2Quantity of substance
If two sheet-type cases are overlapped to form a separation-type battery case, then the battery capacity can be increased, but additional guide units are needed which increases manufacturing costs
Solution Approach 1:
The patent merges the functions of guide units and case separation into a single integrated one-unit sheet-type battery case design. The symmetrical receiving parts and bending line are formed directly in the single laminate sheet, eliminating the need for separate guide units while achieving the same electrode assembly positioning and capacity-doubling effects.
Solution Approach 2:
The one-unit battery case design provides multi-functionality by simultaneously serving as the case structure, the receiving part formation template, and the positioning guide for the electrode assembly. The symmetrical design with bending line performs multiple functions: structural support, receiving part definition, and assembly guidance, replacing what would otherwise require separate components.
3Reliability
If two sheet-type cases are coupled at four sides to form sealing parts, then the battery case is sealed, but the battery case contacts the atmosphere at all four sides which reduces service life
Solution Approach 1:
The patent segments the sealing function by creating a folded configuration where the battery case is bent along a bending line to form overlapping receiving parts. This segmentation allows one sealing part to remain in contact with the atmosphere while the electrode assembly is positioned in the other receiving part, reducing overall atmospheric exposure compared to four-sided contact.
4Manufacturing precision
If the receiving part depth is increased to 15 mm or more, then the electrode assembly can be properly received, but the aluminum laminate sheet breaks during compression
Solution Approach 1:
The patent forms bent depression parts and guide grooves in advance before the final compression step. These pre-formed features create a stress distribution framework that enables the laminate sheet to withstand the compression forces required to achieve receiving part depths of 15 mm or more without breaking.
Solution Approach 2:
The bent depression parts act as intermediary stress-distributing structures that mediate between the compression force and the laminate sheet during receiving part formation. They provide geometric guidance and stress relief, enabling deep receiving parts to be formed while preventing laminate sheet failure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables the production of batteries with twice the conventional capacity without case breakage, ensures accurate electrode assembly positioning, and minimizes atmospheric exposure, thereby increasing the battery's service life and reducing manufacturing defects.
Implementation Method 1
the battery case is bent between the two receiving parts (along a bending line) such that one of the receiving parts overlaps with the other receiving part
Implementation Method 2
thermally welding an additional sheet separated from the laminate sheet or a sheet extending from the laminate sheet to the laminate sheet while the electrode assembly is received in the receiving part
Data Source
AI summary
Disclosed herein is a pouch-type battery including a cathode and an anode protruding from opposite sides of a battery case in opposite directions, wherein the pouch-type battery is constructed in a structure in which two receiving parts are formed at a one-unit sheet-type battery case in a symmetrical fashion such that an electrode assembly is received in the receiving parts, the battery case is bent between the two receiving parts (along a bending line) such that one of the receiving parts overlaps with the other receiving part while the electrode assembly is received in the other receiving part, the bent battery case being scaled, the two receiving parts are continuously formed while the two receiving parts are in contact with the bending line, and the battery case is provided at the edge thereof where the bending line runs with bent depression parts having a depth equivalent to that of the receiving parts. The pouch-type battery is manufactured with a capacity equivalent to twice that of a conventional battery through a simple assembly process, and is constructed in a structure in which the battery case is prevented from breakage during the assembly process.