Prismatic Electrochemical Cell Stacked Electrode Assembly
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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, particularly in vehicles.
Innovation Solution
The electrochemical cell design features a stacked arrangement of electrode plates within a prismatic cell housing, where positive and negative plates are alternately stacked with a z-folded separator, and conductive inner and outer plates form electrical connections, allowing for improved filling of the internal volume and reduced bulging, along with a method of manufacturing using separate housing elements welded together for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional electrode plate arrangement is used, then electrical connection is achieved, but volume efficiency is reduced and battery pack size increases
Solution Approach 1:
The patent merges the electrode plate arrangement with the separator structure by implementing a Z-folded separator that integrates the folding pattern directly into the separator design. This allows the electrode plates to be stacked in a compact alternating pattern while the separator maintains proper spacing and electrical isolation, achieving high volume efficiency without requiring complex external arrangement mechanisms
Solution Approach 2:
The patent transitions from traditional planar electrode arrangement to a three-dimensional stacked configuration where positive and negative electrode plates alternate in layers separated by Z-folded separators. This dimensional transformation allows efficient use of internal volume by utilizing vertical stacking space, reducing the overall battery pack size while maintaining proper electrical connections through the stacked architecture
2Device complexity
If external connectors are used for electrical connections, then connection reliability is achieved, but device complexity and space requirements increase
Solution Approach 1:
The patent extracts and eliminates the need for separate external connectors by integrating the electrical connection function directly into the electrode plate and separator assembly. The Z-folded separator structure itself provides the mechanical and electrical connection pathway, removing the need for additional connector components while maintaining connection reliability through the inherent structural integration
Solution Approach 2:
The Z-folded separator serves multiple functions simultaneously: it provides electrical isolation between adjacent electrode plates of opposite polarity, maintains mechanical spacing, enables compact stacking arrangement, and provides integrated electrical connection pathways. This multi-functionality eliminates the need for separate dedicated connector components, reducing overall device complexity while maintaining reliable electrical connections
Data Source
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AI summary
An electrochemical cell has a cell housing and an electrode assembly disposed in the housing. The electrode assembly includes positive electrode plates alternating with negative electrode plates and separated by at least one separator. An end of each of the positive and negative electrode plates includes a clear lane that is free of active material and includes an opening. An electrically conductive first inner plate extends through the openings in each positive electrode plate, and an electrically conductive second inner plate extends through openings in each negative electrode plate. The positive clear lanes are sandwiched between,and electrically connected to,the first inner plate and a first outer plate. The negative clear lanes are sandwiched between,and electrically connected to,the second inner plate and a second outer plate. The first outer plate is electrically connected to the housing, and the second outer plate is electrically connected to a terminal.