Pouch Cell Tab-Lead Insulation to Prevent Sealing Heat Damage

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Solution Overview

Problem

Conventional pouch cells experience degradation in insulating performance due to heat conduction from the metal portion to the inner insulating layer during the sealing process, leading to adhesion and potential disconnection.

Innovation Solution

A thermal insulator is applied to cover the metal portion within the pouch cell, preventing heat transfer and adhesion between the metal portion and the inner insulating layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the metal portion (electrode tab and electrode lead) is used for electrical connection, then electrical conductivity is improved, but heat conduction causes adhesion to the inner insulating layer during sealing

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidheat conduction to inner insulating layer

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A thermal insulator is introduced as an intermediary component between the metal portion (electrode tab and electrode lead) and the inner insulating layer. This thermal insulator prevents direct heat conduction from the metal portion to the inner insulating layer during the sealing process, thereby preventing adhesion while maintaining the electrical connection function of the metal portion.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The solution employs composite material structure by combining the metal portion (for electrical conductivity) with a thermal insulator material (for thermal insulation). This composite approach allows the system to simultaneously achieve electrical connection reliability and thermal insulation, preventing the harmful adhesion effect.

Inventive Principle:

Principle #40Composite materials

2Reliability

If welding is performed to connect electrode tab and electrode lead, then electrical connection is achieved, but the bead damages the inner surface of the pouch

Engineering Contradiction:

Improveelectrical connectionVSAvoiddamage to pouch inner surface

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The thermal insulator serves as a protective intermediary that covers the welding bead area. This prevents the sharp bead from directly contacting and damaging the inner surface of the pouch, while still allowing the electrical connection to function properly.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The thermal insulator is implemented as a thin film structure that can conform to the metal portion and welding bead. This thin film provides protection against surface damage while maintaining flexibility and not interfering with the electrical connection.

Inventive Principle:

Principle #30Flexible shells and thin films

3Object-affected harmful factors

If thermal insulator is added to cover metal portion, then heat transfer to inner insulating layer is prevented, but device complexity increases

Engineering Contradiction:

Improveheat transfer to inner insulating layerVSAvoidstructure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The thermal insulator is implemented as a thin film rather than a bulky component. This thin film structure provides effective thermal insulation while minimizing space occupation and maintaining simplicity in the overall device structure.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The thermal insulator can be integrated as a composite layer with other pouch components, combining multiple functions (thermal insulation, electrical insulation, mechanical protection) into a single integrated structure, thereby reducing overall complexity.

Inventive Principle:

Principle #40Composite materials

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 use of a thermal insulator effectively minimizes heat transfer to the inner surface of the pouch, maintaining the insulating performance and preventing damage to the pouch surface.

Implementation Method 1

a thermal insulator that covers at least a portion of a portion of the metal portion between the electrode assembly and the lead film

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250192283A1Pouch Cell Including Thermal Insulator Covering Connection Portion of Electrode Tab and Electrode Lead

Publication Date: 2025.06.12 LG ENERGY SOLUTION LTD

AI summary

A pouch battery cell including an electrode assembly, an electrode tab, an electrode lead, and a pouch is provided. The pouch cell includes an electrode tab connected to an electrode assembly and an electrode lead connected to the electrode tab forming a metal portion. The pouch is fusion-sealed over a lead film surrounding the electrode lead to accommodate a portion of a metal portion and the electrode assembly. A thermal insulator is configured to cover at least a portion of a surface of a portion of the metal portion between the electrode assembly and the lead film.