Pouch Cell Terminal Structure for High-Power Charging and Cooling
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Solution Overview
Problem
Conventional electrochemical pouch cells are limited in size and electrical terminal dimensions due to predeformation steps, which restricts power capacity and compatibility with high-power charging, and inadequate cooling leads to overheating and reduced durability.
Innovation Solution
The electrochemical pouch cell design includes a base for the electrical terminal produced in an insulating material with increased dimensions, allowing a larger housing for electrodes, and incorporates a spacing member with a honeycomb structure to accommodate gas and enhance mechanical strength, along with a simplified manufacturing method that avoids predeformation, enabling larger terminals and improved cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the liner is predeformed by stamping to form a cavity, then the cell can accommodate electrodes, but the liner depth is limited by tearing risks and the terminal dimensions are restricted
Solution Approach 1:
The liner is predeformed by folding along crease lines to form a cavity that accommodates the electrodes and terminal assembly. The folding is performed in a controlled manner along predetermined crease lines, allowing deeper cavities without material tearing. This preliminary shaping action enables greater cell volume while maintaining liner integrity.
Solution Approach 2:
The liner is divided into multiple zones with different folding patterns: a first zone with parallel crease lines forming a substantially square cross-section cavity, and a second zone with crease lines at angles forming a substantially circular cross-section cavity. This segmentation allows the liner to achieve complex three-dimensional shapes with greater depth and volume without compromising structural integrity.
2Power
If the electrical terminal dimensions are increased for high-power charging, then fast charging capability is improved, but the seal of the liner on the terminal is compromised
Solution Approach 1:
The design transitions from a simple linear terminal to a multi-dimensional terminal assembly with a base portion and extending portions. The base portion has a first dimension substantially equal to or greater than the electrode stack dimension, while extending portions provide additional dimensional coverage. This multi-dimensional configuration allows the terminal to accommodate high-power connections while maintaining adequate liner contact area for reliable sealing.
Solution Approach 2:
The terminal comprises an insulating material base with metal electrical connectors integrated into it. This composite structure allows the terminal to provide both electrical conductivity for high-power charging and dimensional stability for reliable liner sealing. The insulating base material enables larger terminal dimensions without compromising the seal.
3Quantity of substance
If the cell dimensions are increased to accommodate more energy, then battery capacity is improved, but the terminal section remains small and incompatible with high-power charging
Solution Approach 1:
The terminal base portion is designed with a first dimension on a second axis that is substantially equal to or greater than the first dimension of the electrode stack on the same axis. This dimensional scaling ensures that as the cell grows larger to accommodate more energy, the terminal section area increases proportionally, enabling compatibility with high-power charging infrastructure.
4Temperature
If the cell is cooled on the narrowest face, then cooling is provided, but the useful cooling surface is limited and effective cooling is prevented
Solution Approach 1:
The terminal base portion provides an additional large surface area for cooling that is not limited by the narrowest face of the cell. The base has a first dimension substantially equal to or greater than the electrode stack dimension, creating a substantial cooling surface. This allows cooling systems to access a much larger area, significantly improving heat dissipation capability.
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 design allows for increased power capacity and compatibility with high-power charging while preventing overheating, enhancing durability and reducing manufacturing costs by simplifying the production process.
Implementation Method 1
the at least one primary link can be produced by thermowelding or by bonding
Implementation Method 2
the at least one primary link can be produced by thermowelding or by bonding
Implementation Method 3
The electrochemical cell can store energy in chemical form and restore it in the form of an electrical current
Data Source
AI summary
An electrochemical pouch cell is for an electrical energy storage device, in particular intended for a motor vehicle. The electrochemical cell includes a stack of a plurality of electrodes, at least one electric terminal and a liner connected to the electric terminal and to itself, respectively at a primary connection and a secondary connection, so as to form a recess into which the plurality of electrodes and all or part of the at least one electric terminal extend, the electric terminal having a first dimension substantially equal to or greater than a first dimension of a stack of the plurality of electrodes.