Prismatic Electrochemical Cell Stacked Electrode Volume Efficiency
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Solution Overview
Problem
Existing electrochemical cells face challenges in maximizing the internal volume efficiency due to the orientation and arrangement of electrode plates, leading to large and inefficient battery packs, especially in prismatic cells where the jelly-roll configuration results in outward bulging and reduced space utilization.
Innovation Solution
A method of manufacturing electrochemical cells with a prismatic cell housing that includes a stacked arrangement of electrode plates oriented perpendicular to the major sides of the housing, using a tubular sidewall with separate ends and employing foldable connectors for reliable electrical connections, allowing for improved filling of internal volume and reduced bulging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrode plates are arranged in a jelly-roll configuration, then the cell can be manufactured with a continuous winding process, but the cell housing experiences outward bulging and reduced internal volume efficiency
Solution Approach 1:
The electrode assembly is segmented into discrete stacked plates rather than a continuous jelly-roll winding. Each plate is individually formed and stacked, eliminating the outward bulging effect while maintaining manufacturability through modular assembly processes
Solution Approach 2:
The electrode plates are oriented perpendicular to the major sides of the prismatic cell housing, changing the traditional parallel orientation. This dimensional reorientation allows for more efficient space utilization and reduces bulging effects on the cell housing
2Ease of manufacture
If electrode plates are oriented parallel to the major sides of the cell housing, then the stacking process is simplified, but the internal volume efficiency is reduced due to increased bulging
Solution Approach 1:
The electrode plates are oriented perpendicular to the major sides of the cell housing, creating an asymmetric arrangement that optimizes space utilization. This orientation reduces the bulging effect on the cell housing while maintaining efficient stacking and assembly processes
3Strength
If the cell housing is formed as a single integral piece, then the structural strength is maximized, but the manufacturing complexity and cost increase
Solution Approach 1:
The cell housing is divided into separate components (sidewall, end caps) that are manufactured independently and then assembled. This segmentation reduces manufacturing complexity and cost while maintaining structural strength through proper joining methods
Solution Approach 2:
The electrical connectors are attached to the electrode assembly before insertion into the cell housing. This preliminary action simplifies the overall assembly process and reduces manufacturing complexity while maintaining reliable electrical connections
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 approach enhances the internal volume efficiency of the cell housing by optimizing the electrode arrangement and orientation, reducing bulging, and simplifying the electrical connection process, thereby improving the overall performance and compactness of the battery pack.
Implementation Method 1
welding the cell housing first end to one end of the cell housing sidewall and welding the cell housing second end to an end of the cell housing sidewall opposed to the one end of the cell housing sidewall
Data Source
AI summary
A method of manufacturing an electrochemical cell is provided. The cell includes a rigid housing and an electrode assembly disposed in the housing. The method includes providing a housing that includes a first end, a second end formed separately from the first end, and a tubular sidewall formed separately from each of the first end and the second end. After the electrode assembly is inserted into the sidewall, the first end is welded to one end of the sidewall, and the second end is welded to the other end of the sidewall.