Folded Pouch Case Layout for Variable-Thickness Secondary Batteries
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Solution Overview
Problem
Conventional pouch type secondary battery manufacturing processes are limited by mechanical and physical properties of materials, leading to defects like warpage and restricted shape and size, and high material costs due to the need for foaming processes.
Innovation Solution
A pouch type secondary battery with a pouch case formed by folding space-forming sections and tab drawing sections, eliminating the need for foaming processes, allowing for variable thickness and reduced material costs by selecting materials based on mechanical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a foaming process is used to form the pouch space, then the pouch can be formed with specific shape and size, but the material costs increase and the cell thickness is limited
Solution Approach 1:
The invention changes the physical state and properties of the pouch case material from a foamed structure to a non-foamed, foldable structure. By eliminating the foaming process and using folding operations, the patent achieves variable thickness and eliminates material cost limitations while maintaining the required pouch shape and size.
Solution Approach 2:
The pouch case is divided into multiple space-forming sections that can be independently folded along imaginary lines. This segmentation allows the pouch to achieve complex three-dimensional shapes through folding operations rather than requiring a monolithic foamed structure, thereby reducing material costs and enabling variable thickness.
2Productivity
If conventional pouch forming processes are used, then the pouch can be manufactured, but defects such as warpage occur and the shape and size are limited due to material properties
Solution Approach 1:
The pouch case is designed with pre-marked imaginary lines and pre-configured space-forming sections that guide the folding process. This preliminary structuring ensures that the pouch achieves the desired shape and size with high precision, eliminating warpage defects that occur in conventional processes where the material is forced into shape after formation.
3Ease of manufacture
If the pouch case is designed with fixed thickness for foaming processes, then manufacturing is simplified, but the cell thickness cannot be varied
Solution Approach 1:
The pouch case transitions from a static, fixed-thickness foamed structure to a dynamic, foldable structure where the effective thickness can be varied by changing the folding configuration. The space-forming sections can be folded to different degrees, allowing the same pouch case design to accommodate different cell thickness requirements without changing the manufacturing process complexity.
Data Source
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AI summary
The present invention provide a pouch type secondary battery and a method for manufacturing the same. More particularly, the present invention provides a pouch type secondary battery and a method for manufacturing the same, in which a pouch case is formed in a folding manner without being subjected to a forming process (press process), such that there is no limit in a length, and a thickness of an inner space of the pouch case is not limited.