Pouch Cell Sealing Fold Layout for Insulation Integrity
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Solution Overview
Problem
During the sealing process of battery cells, the deformation of the insulating resin layer can lead to insulation breakdown, causing damage to other components and compromising the integrity of the pouch.
Innovation Solution
A battery cell design featuring a pouch with a metal layer and insulating resin layers, where a first sealing tool forms a deformed region to create a folding line between the electrode assembly and the deformed region, and a second sealing tool further seals the pouch with a wider deformed region, reducing insulation destruction and enhancing space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sealing tool transmits pressure to the pouch to seal the pouch, then the sealing is achieved, but the insulating resin layer is deformed and insulation may be destroyed
Solution Approach 1:
The sealing process is divided into two distinct stages: first sealing the pouch at normal position, then folding the sealing portion and performing second sealing. This segmentation allows the insulating resin layer to be protected from excessive deformation during the critical folding operation, while still achieving complete sealing integrity through the subsequent second sealing step.
Solution Approach 2:
The pouch is sealed in its normal position before the folding operation is performed. This preliminary sealing action ensures that the pouch is already sealed while the insulating resin layer is still in its original position, preventing insulation breakdown that would occur if sealing were attempted after folding.
2Volume of moving object
If the sealing portion is bent to increase space utilization, then space efficiency is improved, but the insulating resin layer extends to the bent region and insulation is destroyed
Solution Approach 1:
The sealing portion is divided into a first sealing portion (before folding) and a second sealing portion (after folding). The first sealing portion is sealed while flat, maintaining insulation integrity. The second sealing portion is then folded to achieve space utilization goals, with the understanding that insulation protection was already secured in the first portion.
Solution Approach 2:
The critical sealing operation is performed on the first sealing portion before the folding action takes place. This preliminary sealing ensures that the insulating resin layer remains in its protected position during the subsequent folding operation that improves space utilization.
3Device complexity
If a single sealing tool is used to seal the pouch, then the manufacturing process is simple, but the insulating resin layer deformation cannot be controlled
Solution Approach 1:
The sealing process is segmented into two distinct operations performed by separate sealing tools: first sealing tool seals the pouch in its normal position, and the second sealing tool seals the folded sealing portion. This segmentation provides precise control over deformation at each stage, preventing insulation breakdown while maintaining manufacturing efficiency.
Solution Approach 2:
The first sealing tool performs the preliminary sealing action on the insulating resin layer before it undergoes folding deformation. This timing control ensures that the resin layer is secured in its optimal position, and the second sealing tool then completes the sealing after folding without compromising insulation 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
This solution effectively prevents insulation breakdown during sealing, ensuring the integrity of the battery cell and improving energy density by strategically managing the deformation of the insulating resin layer.
Implementation Method 1
When a sealing tool transmits pressure to the pouch to seal the pouch
Implementation Method 2
a portion of the insulating resin layer of the pouch may be deformed
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A battery cell includes an electrode assembly; a pouch including an accommodation portion accommodating the electrode assembly and a sealing portion sealing at least a portion of the accommodation portion; and an electrode lead connected to the electrode assembly. The sealing portion includes a first sealing portion surrounding at least a portion of the electrode lead, and a second sealing portion extending from the first sealing portion and including at least a portion folded with respect to a folding line. The pouch includes a metal layer forming an exterior of the pouch, an insulating resin layer disposed below the metal layer, and a deformed region extending from the insulating resin layer. The folding line is disposed between the electrode assembly and the deformed region.