Stacked Battery Monocell Assembly for Scalable Cell Manufacturing
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Solution Overview
Problem
Existing manufacturing processes for battery cells with stacked electrodes lack efficiency and scalability, particularly for large arrays used in electric vehicles, where the assembly of multiple electrode stacks into battery cells is complex and time-consuming.
Innovation Solution
A method for manufacturing battery cells involves generating monocells with anode, cathode, and separators, then stacking and arranging these monocells within a cell container, optionally using spring or foam elements to accommodate expansion and contraction, and connecting conductive tabs to battery terminals via expandable weld tabs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing processes are used for battery cells with stacked electrodes, then the assembly process can handle complex electrode stacks, but the manufacturing efficiency and scalability are low
Solution Approach 1:
The battery cell assembly is segmented into multiple independent battery monocells, each containing a complete set of electrodes and separators. These monocells can be manufactured separately and then stacked in sequence, transforming a complex single-step assembly into a modular multi-step process that improves efficiency and scalability
Solution Approach 2:
The electrodes and separators are pre-assembled into complete battery monocells before the final stacking operation. This preliminary assembly allows for standardized manufacturing of individual units that can be rapidly stacked, reducing the complexity of the overall manufacturing process while improving productivity
2Quantity of substance
If multiple battery monocells are stacked to form large arrays, then the energy capacity increases, but the mechanical stresses from expansion and contraction during charging and discharging increase
Solution Approach 1:
Spring elements are introduced between stacked battery monocells to provide mechanical compliance. These springs allow the assembly to accommodate expansion and contraction stresses during charging and discharging cycles, distributing and reducing mechanical stress across the entire stack while maintaining the high energy capacity provided by multiple monocells
Solution Approach 2:
Spring elements and foam elements are pre-positioned between battery monocells to cushion against mechanical stresses before they occur during charging and discharging cycles. This beforehand cushioning protects the electrode structures from damage while allowing the large array configuration to maintain its high energy capacity
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 method enables the efficient and scalable manufacturing of battery cells with stacked electrodes, improving the assembly process for large arrays by simplifying the stacking and connection of monocells, while also accommodating the mechanical stresses associated with charging and discharging.
Implementation Method 1
arranging one or more spring elements between the first and second battery monocells
Implementation Method 2
arranging a foam element between the first and second battery monocells
Data Source
AI summary
A method of manufacturing a battery cell includes providing a battery cell container. The method also includes generating a first battery monocell having a respective anode, cathode, first separator arranged therebetween, and a second separator arranged adjacent to the corresponding anode. The method additionally includes generating a second battery monocell having a respective anode, cathode, first separator arranged therebetween, and a second separator arranged adjacent to the corresponding anode. The method also includes stacking the first battery monocell and the second battery monocell such that the second separator of the first battery monocell is adjacent to the cathode of the second battery monocell. The method further includes arranging the stacked first and second battery monocells in the battery cell container.