Stacked Electrochemical Cell Fit Structure for Connection Reliability

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Solution Overview

Problem

Existing electrochemical cells face challenges in maintaining reliable electrical connections and protecting internal components from external environments due to misregistration and potential stress on fit portions, which can lead to performance impairment and increased risk of damage.

Innovation Solution

The electrochemical cell design incorporates a stacked configuration with a fit portion that uses convexities and concavities on the inner containers to securely fix unit cells within an outer container, distributing external forces and reducing the risk of misregistration, while the outer container employs a multi-layer structure with a moisture-proof layer to shield the cells from oxygen and water.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If unit cells are stacked together in an electrochemical cell, then the capacity and voltage can be increased, but misregistration and stress on fit portions occur leading to unreliable electrical connections

Engineering Contradiction:

Improvenumber of unit cellsVSAvoidelectrical connection reliability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent divides the inner container into multiple independent unit cells, each with its own housing and electrodes. This segmentation allows each cell to be independently positioned and connected, reducing the impact of misregistration between cells and maintaining reliable electrical connections even when multiple cells are stacked

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces an intermediary structure (the fit portion with convexity and concavity) between adjacent unit cells to facilitate precise positioning and stable electrical connections. This intermediary mechanism compensates for potential misregistration and ensures reliable connections without directly relying on perfect alignment between cell components

Inventive Principle:

Principle #24Intermediary (Mediator)

2Use of energy by moving object

If unit cells are stacked together to increase capacity, then energy storage is improved, but external forces can cause misregistration and damage to internal components

Engineering Contradiction:

Improveenergy storage capacityVSAvoidprotection of internal components

Core Design Contradiction:

Use of energy by moving objectVSStrength

Solution Approach 1:

The patent incorporates a fit portion with convexity and concavity that acts as a cushioning mechanism before external forces can reach the internal components. This pre-positioning structure absorbs and distributes external shocks and forces, preventing direct transmission to the electrodes and other sensitive internal components

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent employs a nested structure where the first inner container is placed within the second outer housing. This nested arrangement provides multiple layers of protection, with the outer housing shielding the inner container and its contents from external environmental factors and mechanical forces

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If a simple container structure is used, then manufacturing is easier, but the cells are vulnerable to oxygen and water ingress

Engineering Contradiction:

Improvecontainer structure simplicityVSAvoidmoisture and oxygen protection

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent uses a nested container structure where the first inner container is housed within the second outer housing. This nested design provides enhanced protection against moisture and oxygen ingress without significantly complicating the manufacturing process, as each container can be manufactured separately and then assembled

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent employs composite material structures for the inner and outer containers, combining materials with different properties to achieve both protective functionality and manufacturing feasibility. The use of resin materials and sealing structures creates a composite system that effectively blocks moisture and oxygen while remaining manufacturable

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12142782B2Electrochemical cell

Publication Date: 2024.11.12 KYOCERA CORP

AI summary

An electrochemical cell includes a first unit cell including a first power generation element and a first inner container which accommodates the first power generation element; a second unit cell including a second power generation element and a second inner container which accommodates the second power generation element; an outer container which accommodates the first unit cell and the second unit cell. A surface of the first inner container is provided with a convexity that has a curved surface and/or a flat surface, and a surface of the second inner container is provided with a concavity that has a curved surface and/or a flat surface. The electrochemical cell includes a fit portion in which the convexity is fitted in the concavity.