Pouch Battery Cell Tab Layout to Reduce Module Dead Space
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Solution Overview
Problem
The size of the electrode assembly in secondary battery cells is limited by the space occupied by the electrode tab extending outside the pouch, leading to dead space and reduced energy density.
Innovation Solution
The electrode tab is located inside the pouch with a through-hole in the sealing portion, allowing partial exposure and connection to external components, and sealed with a sealant to prevent electrolyte leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electrode tab extends to the outside of the pouch, then electrical connection to external components is achieved, but the size of the electrode assembly is limited and dead space occurs in the battery module
Solution Approach 1:
The electrode tab is nested inside the pouch structure rather than extending externally. The tab is positioned within the sealing portion of the pouch, allowing electrical connection while eliminating the need for external extension that would create dead space in the battery module.
Solution Approach 2:
The electrode tab is repositioned from an external extension to an internal component within the pouch's sealing portion. This dimensional reconfiguration allows the tab to maintain electrical connectivity while occupying space that would otherwise be wasted, thereby reducing dead space in the overall battery module.
2Volume of stationary object
If the electrode tab is located inside the pouch, then dead space is reduced and energy density is improved, but the electrode tab must be exposed through a through-hole for external connection
Solution Approach 1:
The sealing portion of the pouch serves multiple functions: it seals the electrode assembly, contains the electrode tab, and incorporates the through-hole for electrical connection. This multi-functional design integrates the connection feature into the existing sealing structure rather than adding separate external connection components.
Solution Approach 2:
The through-hole is created locally within the sealing portion at a specific location to allow electrode tab exposure. This localized modification maintains the integrity of the overall pouch structure while providing the necessary electrical connection point, minimizing the impact on the overall design.
3Ease of operation
If the through-hole is formed in the sealing portion, then the electrode tab can be exposed for external connection, but electrolyte leakage may occur through the hole
Solution Approach 1:
A sealant is introduced as an intermediary substance to fill and seal the gap between the electrode tab and the sealing portion around the through-hole. This sealant prevents electrolyte leakage while allowing the electrode tab to pass through for electrical connection, thus maintaining both connectivity and reliability.
Solution Approach 2:
The sealant is applied in advance to the through-hole area before final assembly, creating a protective barrier that prevents electrolyte leakage. This proactive sealing approach ensures that potential leakage paths are blocked before they can cause problems during battery operation.
Data Source
AI summary
A battery cell includes an electrode assembly, a pouch including an electrode accommodating portion accommodating the electrode assembly and a sealing portion surrounding at least a portion of the electrode accommodating portion, and an electrode tab electrically connected to the electrode assembly and located inside the pouch. The pouch may include a through-hole formed in the sealing portion, and the electrode tab may be exposed to the outside of the pouch through the through-hole.