Pouch Battery Terminal End Caps for Stable Compact Cell Packaging
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Solution Overview
Problem
Existing battery cell designs lack sufficient rigidity and stability, leading to potential tab wear and tearing, and require larger packaging space, which affects battery performance and efficiency.
Innovation Solution
The implementation of rigid terminal end caps for pouch-type battery cells, which are integrated with flexible pouch walls and electrically connected to the electrode stack, enhancing cell stability and allowing for more compact and efficient packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid terminal end caps are added to pouch-type battery cells, then cell stability and robustness are improved, but device complexity increases
Solution Approach 1:
The terminal end cap integrates multiple functions into a single component: it provides mechanical reinforcement to the pouch cell, serves as an electrical terminal for current collection, and acts as a sealing element. This merging of functions reduces the need for separate components while improving cell stability.
Solution Approach 2:
The terminal end cap is constructed from composite materials that combine electrical conductivity with mechanical strength. This allows the single component to simultaneously provide electrical connection and structural reinforcement without requiring additional separate parts.
2Strength
If rigid terminal end caps are integrated with flexible pouch walls, then cell robustness is improved, but manufacturing complexity increases
Solution Approach 1:
The terminal end cap is pre-assembled with the electrical terminal embedded in the rigid polymeric cap body before integration with the pouch cell. This preliminary assembly simplifies the final integration step and ensures proper alignment and electrical connection.
Solution Approach 2:
The rigid polymeric cap body serves as an intermediary component that bridges the flexible pouch walls and the electrical terminal. It provides a stable mounting surface for the terminal while maintaining flexibility compatibility with the pouch structure.
3Reliability
If terminal end caps are embedded with electrical terminals, then electrical connection stability is improved, but packaging space requirements increase
Solution Approach 1:
The electrical terminal is embedded within the rigid polymeric cap body, merging the electrical connection function with the structural support function. This integration eliminates the need for separate terminal mounting structures and reduces overall space requirements.
Solution Approach 2:
The electrical terminal is nested within the rigid polymeric cap body, with the terminal housed inside the cap structure. This nesting arrangement allows the terminal to be protected and secured while minimizing the external dimensions of the assembly.
Data Source
AI summary
Presented are terminal end caps for pouch-type battery cells, vehicles equipped with rechargeable battery packs containing such pouch cells, and methods for making/using such caps, cells, and/or vehicles. A battery cell assembly includes a cell pouch with flexible pouch walls that are joined along a peripheral seam to define one or more openings at one or both ends of the cell pouch. Located inside the cell pouch is an ion-conducting electrolyte and one or more pairs of working electrodes in electrochemical contact with the electrolyte. Also located inside the cell pouch and interposed between each pair of working electrodes is an electrically isolating separator sheet. A terminal end cap is located in each pouch opening and attached to the pouch walls. Each terminal end cap includes a rigid polymeric cap body with one or more electrical terminals embedded in the cap body and electrically connected to at least one electrode.