Pouch Cell Pressure Homogenizing Layers for Dendrite Control

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Solution Overview

Problem

Lithium-ion pouch cells experience inhomogeneous current density and dendrite formation due to uneven pressure distribution, which affects safety and cyclability.

Innovation Solution

Implementing a layered pressure homogenizing soft medium between the battery pouches and an external pressure mechanism to ensure uniform pressure distribution using pressure sensors and controllers to adjust pressure within a desired range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stress or pressure

If a single pressure mechanism is applied directly to battery pouches, then pressure can be applied to the pouches, but the pressure distribution becomes inhomogeneous causing uneven current density and dendrite formation

Engineering Contradiction:

Improvepressure distributionVSAvoidsafety and cyclability

Core Design Contradiction:

Stress or pressureVSReliability

Solution Approach 1:

The pressure homogenizing medium is divided into multiple layers with different thicknesses and physical properties. Each layer segments the pressure transmission path, allowing gradual homogenization of pressure across the battery pouch surface, preventing localized high-pressure spots that cause dendrite formation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The layered pressure homogenizing medium acts as an intermediary between the pressure mechanism and the battery pouches. This intermediate layer transforms the concentrated pressure from the pressure mechanism into a distributed, homogeneous pressure field across the pouch surface, eliminating direct contact and preventing pressure concentration.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If pressure is increased to improve contact and current density, then electrical performance improves, but dendrite formation increases reducing safety

Engineering Contradiction:

Improvecurrent density uniformityVSAvoiddendrite formation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Different layers of the pressure homogenizing medium have different local properties (thickness, material composition, compressibility) optimized for specific functions. The varying layer properties create a gradient that distributes pressure evenly across different regions of the battery pouch, ensuring uniform current density without creating localized high-pressure zones that would induce dendrites.

Inventive Principle:

Principle #3Local quality

3Stress or pressure

If a layered pressure homogenizing medium is introduced, then pressure distribution becomes uniform, but device complexity increases

Engineering Contradiction:

Improvepressure homogeneityVSAvoidstructure complexity

Core Design Contradiction:

Stress or pressureVSDevice complexity

Solution Approach 1:

The pressure homogenizing medium consists of thin, flexible layers that can be easily integrated into the battery structure. These thin-film layers provide the necessary pressure distribution function without adding significant structural complexity or volume, maintaining simplicity while achieving homogeneous pressure distribution.

Inventive Principle:

Principle #30Flexible shells and thin films

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

The solution provides even pressure distribution across the surface of pouch cells, minimizing dendrite formation and enhancing uniform current density, thereby improving safety and performance.

Implementation Method 1

a layered pressure homogenizing soft medium that is disposed between the battery pouches and the pressure mechanism

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the battery pouches disposed between the pressure homogenizing medium layers are evenly pressurized by the mediums due to pressure applied by the pressure mechanism to within a desired range of pressure

Methodology Applied

Scientific EffectPressure homogenization: Pressure Gradient

Implementation Method 3

The pressure applied to the battery pouches by the pressure homogenizing medium is monitored by a pressure sensor, such as a two-dimensional pressure sensor

Methodology Applied

Scientific EffectPressure sensing: Piezoresistive Effect

Data Source

PatentUS12567601B2Systems and methods for a battery utilizing separate pressure homogenizing medium layers between a battery pouch and a plane jig

Publication Date: 2026.03.03 TERAWATT TECHNOLOGY INC

AI summary

A battery cell having a layered pressure homogenizing soft medium for liquid/solid state Li-ion rechargeable batteries. The battery cell of the present technology includes one or more battery pouches, a pressure mechanism external to the battery pouches that applies a pressure to the battery pouches, and a layered pressure homogenizing soft medium that is displaced between the battery pouches and the pressure mechanism. By using a number of pressure homogenizing medium layers, each with a specific range of thickness and within a range of physical properties, the battery pouches displaced between the pressure homogenizing medium layers are evenly pressurized by the mediums due to pressure applied by the pressure mechanism to within a desired range of pressure. The pressure applied to the battery pouches by the pressure homogenizing medium is monitored by a pressure sensor, such as a two-dimensional pressure sensor. If the pressure to the battery pouches is not within a desired pressure range, a controller can control the pressure mechanism to adjust the pressure to the mediums and battery pouches to bring the pressure within the desired range.