Stacked Prismatic Cell Tab Layout for High-Layer Welding Durability
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Solution Overview
Problem
Current battery cell manufacturing techniques are limited by the durability of electrode tabs during welding, leading to degradation issues and a restricted number of layers in stacked prismatic cells, along with a lack of safety features for gas release in high-power batteries.
Innovation Solution
The battery cell system employs laterally offset electrode tabs to reduce the thickness and increase the number of electrodes, using a structural frame and protective housing with a rupture disc vent for enhanced durability and safety, allowing for up to 150 layers and improved gas management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of electrode layers is increased to increase battery capacity, then the battery capacity increases, but the electrode tabs become more susceptible to degradation due to increased welding intensity
Solution Approach 1:
The electrode tabs are segmented into multiple groups along the stacking direction, with each group containing tabs from a subset of electrodes. This segmentation reduces the number of tabs that need to be welded together at each welding point, thereby reducing welding intensity and preventing tab degradation while still allowing for a high number of electrode layers (up to 150 layers) to achieve high battery capacity.
2Ease of manufacture
If conventional welding techniques are used to weld all electrode tabs together, then all tabs are connected, but the welding intensity causes tab degradation such as melting and deformation
Solution Approach 1:
The electrode tabs are divided into multiple groups along the stacking direction, with each group containing tabs from a subset of electrodes. This segmentation reduces the welding intensity at each connection point, preventing tab degradation such as melting and deformation while still achieving complete electrical connection across all electrodes through the series of grouped welds.
3Quantity of substance
If the housing thickness is increased to accommodate more electrode layers, then more layers can be included, but the housing manufacturing limitations restrict the depth to 15 mm
Solution Approach 1:
The electrode tabs are arranged in multiple groups along the stacking direction (vertical dimension), allowing electrodes to be connected through the thickness of the housing. This dimensional arrangement enables accommodation of up to 150 electrode layers within the 15 mm housing thickness constraint by optimizing the vertical distribution and grouping of tabs rather than increasing housing depth.
4Shape
If aluminum housing material is stretched during conventional forming processes, then the housing shape is formed, but the material thickness is reduced thereby reducing the strength of the material
Solution Approach 1:
The housing forming process parameters are optimized to minimize material thinning during shaping. By controlling forming temperature, pressure, and tooling design, the aluminum housing material maintains its thickness and strength properties while still achieving the required prismatic shape to accommodate the stacked electrode structure.
Data Source
AI summary
A battery cell system and method for manufacturing a battery cell system is provided. The battery cell system includes an electrode stack including a first anode with a first anode tab, a second anode with a second anode tab laterally offset from the first anode tab, a first cathode with a first cathode tab, and a second cathode with a second cathode tab laterally offset from the first cathode tab.