Rigid Frame Battery Cell with Integrated Terminals
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Solution Overview
Problem
Lithium ion pouch cells face challenges such as incomplete sealing around terminals leading to leaks, pre-forming complexities that increase cost and risk of distortion, limited mechanical protection, inadequate thermal conduction, and lack of integrated features for sensors and electronic devices.
Innovation Solution
A lithium ion pouch battery cell design featuring a rigid frame with integrated terminals, a flexible polymeric cell cover, and internal fluid channels, along with electronic communication devices, providing enhanced sealing, mechanical protection, thermal management, and the ability to incorporate sensors and electronic features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminals are integrated into the frame with molded sealing, then sealing reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The terminal and sealing structure are merged into a single integrated component molded from the frame material. The terminal protrudes from the frame with a sealing structure that forms a continuous sealed barrier between the terminal interior and the cell interior, eliminating separate sealing components and assembly steps while ensuring reliable sealing.
Solution Approach 2:
The molded terminal structure serves multiple functions simultaneously: it provides electrical connection through the terminal, mechanical support through the frame integration, and sealing through the integrated sealing structure. This multi-functionality reduces the number of separate components needed while improving sealing reliability.
2Strength
If a rigid frame structure is added for mechanical protection, then mechanical integrity is improved, but weight increases
Solution Approach 1:
The rigid frame is provided only at the periphery of the cell where mechanical protection is most needed, rather than enclosing the entire cell. The frame defines the aperture and provides structural support at critical locations while leaving the cell interior open and flexible, thus providing mechanical integrity without excessive weight increase.
Solution Approach 2:
The frame is formed from a molded material that combines rigidity for structural support with properties compatible with the cell's thermal and electrical requirements. The integration of terminals and sealing structures into this composite frame structure optimizes the strength-to-weight ratio by eliminating the need for additional protective components.
3Productivity
If pre-forming is used to prepare the cell structure, then packaging efficiency is improved, but distortion risk increases
Solution Approach 1:
The frame and terminals are pre-formed through molding to define the cell aperture and terminal positions before cell assembly. This preliminary structuring provides packaging efficiency and alignment features while the flexible cell interior and envelope structure accommodate subsequent assembly steps without requiring high-precision pre-forming of the entire cell, thus reducing distortion risk.
4Temperature
If fluid channels are integrated into the frame, then thermal conduction is improved, but device complexity increases
Solution Approach 1:
The fluid channels are integrated directly into the frame structure during molding, combining the thermal management function with the structural frame. The channels are formed as hollow passages within the frame material, allowing coolant flow for thermal conduction without requiring separate thermal management components or complex assembly operations.
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 improves sealing reliability, reduces manufacturing complexity, enhances mechanical integrity, improves thermal conduction, and allows for the integration of sensors and electronic devices, addressing the limitations of existing pouch cell technologies.
Implementation Method 1
an outward thermally conductive portion surrounding the inward portion
Data Source
AI summary
A lithium ion pouch battery cell includes a rigid frame forming a skeleton of the cell and defining an aperture, an anode, a separator, and a cathode disposed within the aperture. The anode and cathode each include a current collector with an exposed tab portion, and a pair of terminals, integrated into the frame, each having an exterior portion and an interior portion bonded to one of the current collectors.