Pouch Secondary Battery Packaging With Support Frame Structure
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Solution Overview
Problem
The limitations in forming a cup portion for accommodating an electrode assembly in pouch-type secondary batteries lead to constraints on increasing battery capacity and result in defects such as cracks due to material thickness limitations and forming depth restrictions.
Innovation Solution
A secondary battery design incorporating a support frame surrounding the electrode assembly and a sheet-type outer packaging material that forms an accommodation space without the need for a cup portion, allowing for increased capacity and material selection freedom, while minimizing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a cup portion is formed in the pouch film to accommodate the electrode assembly, then the battery capacity can be increased, but the forming depth is limited by material characteristics and cracks may occur
Solution Approach 1:
The outer packaging structure is divided into two functional parts: a rigid support frame that provides structural support and defines the accommodation space, and a pouch film that seals the battery components. This segmentation allows the support frame to bear the mechanical stress of deep forming while the pouch film maintains integrity through sealing operations.
Solution Approach 2:
The support frame acts as an intermediary structure between the pouch film and the electrode assembly. It provides the necessary structural framework for deep cup portion formation without requiring the pouch film itself to undergo deep forming, thereby preventing cracks while enabling increased battery capacity.
2Manufacturing precision
If the pouch film thickness is reduced to achieve better sealing, then sealing quality improves, but cracks occur during cup portion forming
Solution Approach 1:
The packaging system is segmented into a thick support frame for structural strength and a thin pouch film for precise sealing. The support frame absorbs the mechanical stress during forming, allowing the pouch film to be thin enough for high-quality sealing without compromising overall strength.
Solution Approach 2:
The outer packaging system uses a composite structure combining a rigid support frame material (providing strength and stiffness) with a flexible pouch film material (providing sealability). This composite approach allows optimization of each material for its specific function without compromise.
3Quantity of substance
If the cup portion forming depth is increased to accommodate more electrode assembly, then battery capacity increases, but material characteristics limit the forming depth
Solution Approach 1:
The accommodation space formation is segmented into two stages: first, the support frame is formed with a deep cup portion structure through conventional forming processes; second, the pouch film is sealed around the support frame structure. This allows deep forming without requiring the pouch film to undergo the entire forming depth.
Solution Approach 2:
The support frame is pre-formed with the deep cup portion structure before the pouch film sealing process. This preliminary action allows the pouch film to simply conform to the pre-formed structure rather than undergoing deep forming itself, making the manufacturing process easier while achieving deep accommodation space.
Data Source
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AI summary
A secondary battery according to an embodiment of the present disclosure may include an electrode assembly, a support frame surrounding a part of the electrode assembly, a sheet-type outer packaging material surrounding a remaining part of the electrode assembly to form an accommodation space accommodating the electrode assembly together with the support frame, and coupled to the support frame to define the accommodation space separated from outside of the support frame, and an electrode terminal electrically connected to an electrode tab of the electrode assembly, and disposed in the sheet-type outer packaging material such that it is exposed to outside of the sheet-type outer packaging material.