Pouch Cell Protector Structure for Tab-End Impact Reinforcement
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Solution Overview
Problem
Pouch-type lithium-ion batteries face mechanical reliability issues due to the low strength of aluminum laminated films, leading to risks of electrolyte leakage and failure from impacts, which can cause thermal runaway and explosion.
Innovation Solution
The integration of a protector structure at the end of the battery cell, which covers the tab and extends to the lateral faces, providing reinforcement and a cooling effect, while maintaining a frangible structure for pressure relief, and optionally including additional protectors for enhanced protection and material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If aluminum laminated film is used for packaging, then energy density and adaptability are improved, but mechanical strength and reliability deteriorate
Solution Approach 1:
The patent applies composite materials by combining aluminum laminated film with protective structures including rigid protective shells, reinforcing ribs, and impact-absorbing materials. This composite approach maintains the high energy density benefit of aluminum packaging while compensating for its mechanical weakness through additional protective layers and structural reinforcements.
Solution Approach 2:
The protective structure is segmented into multiple functional components: a rigid protective shell, reinforcing ribs at critical locations, frangible sections for pressure relief, and impact-absorbing elements. This segmentation allows each component to perform its specific function optimally while working together to provide comprehensive protection.
2Weight of moving object
If aluminum laminated film is used for packaging, then weight is reduced, but resistance to impact and mechanical damage deteriorates
Solution Approach 1:
The patent implements beforehand cushioning by incorporating impact-absorbing materials and energy-dissipating structures within the protective shell. These elements are pre-positioned to absorb and dissipate impact energy before it reaches the battery cell, reducing the effect of mechanical shocks and drops while maintaining lightweight construction.
Solution Approach 2:
The protective structure utilizes flexible yet strong materials including thin-walled but reinforced polymers and composite films that provide impact resistance without significant weight increase. These materials offer a favorable strength-to-weight ratio while maintaining the lightweight advantage of aluminum packaging.
3Reliability
If protective structure is added to reinforce the battery, then mechanical reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into an integrated protective structure that combines mechanical protection, thermal management, pressure relief, and impact absorption in a single unified design. This integration reduces the number of separate components and assembly steps, thereby limiting the increase in device complexity while achieving comprehensive protection.
Solution Approach 2:
The protective structure is designed with multi-functionality, serving as both mechanical reinforcement and thermal management component, while also incorporating pressure relief capabilities. This universal design approach allows a single structure to address multiple concerns simultaneously, reducing overall system complexity.
4Reliability
If frangible structure is added for pressure relief, then safety in thermal runaway is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent applies local quality by implementing frangible sections only at specific critical locations where pressure relief is most needed, such as the top seal region and corners prone to bursting. The majority of the protective structure maintains full mechanical strength, while localized frangible areas provide pressure relief pathways without significantly compromising overall structural integrity.
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 protector structure enhances the mechanical reliability of the battery cell by preventing burst openings and electrolyte leakage, while maintaining the safety features of pressure relief and cooling, thus improving the battery's resistance to mechanical stress and thermal events without compromising the packaging design.
Implementation Method 1
by using the hot-melt and heat-absorbing effects of the first protector, the first protector can exert some cooling effect on the electrochemical device
Data Source
AI summary
An electrochemical device, a battery pack, and an electrical device to alleviate the problem of inferior mechanical properties of existing electrochemical devices. The electrochemical device provided includes a body and a first protector. The first protector is disposed at an end of the body, where the end is provided with the tab. A part of the tab is disposed in the first protector, and another part of the tab extends out of the first protector.