Stacked Electrochemical Cell Welding for Secure Multi-Cell Assembly

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Solution Overview

Problem

Existing electrochemical cells face challenges in efficiently stacking and securing multiple power generation elements within a compact, reliable, and protective structure, which can lead to electrical connection issues and increased thickness at fixed portions, compromising the cell's reliability and performance.

Innovation Solution

The electrochemical cell design incorporates a stacked configuration of multiple single cells, each with a power generation element and inner container, connected in parallel or series, and an outer container that protects them from environmental factors, with a welded portion securing the inner containers to maintain electrical integrity and reduce displacement risks, utilizing materials like polyethylene terephthalate and ultrasonic welding for enhanced reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple power generation elements are stacked to increase capacity and voltage, then the energy output is improved, but the structural complexity and difficulty of securing them reliably increases

Engineering Contradiction:

Improveenergy outputVSAvoidstructural complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The battery is divided into multiple single cells, each containing a power generation element and an inner container. These single cells are stacked to form the complete battery, allowing modular assembly and simplified manufacturing of high-capacity batteries without requiring complex monolithic structures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple single cells are stacked and secured together within an outer container to form a unified battery structure. The inner containers of adjacent single cells are welded together, merging them into a cohesive assembly that maintains electrical integrity while achieving the desired energy output.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If inner containers are welded to secure single cells, then electrical connection integrity is improved, but the manufacturing process complexity increases

Engineering Contradiction:

Improveelectrical connection integrityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The welding process replaces mechanical fastening methods (such as screws or clips) to join the inner containers of single cells. This substitution provides superior electrical connection integrity and mechanical strength, while the welding process itself is well-established in battery manufacturing, minimizing the increase in manufacturing complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Quantity of substance

If single cells are stacked to increase capacity, then the energy storage is improved, but the risk of displacement and external force damage increases

Engineering Contradiction:

Improveenergy storageVSAvoiddisplacement resistance

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

Single cells are nested within the outer container, with inner containers of adjacent cells welded together to form a integrated structure. This nesting arrangement, combined with welding, ensures that stacked cells remain securely positioned and resistant to displacement under external forces, while maximizing the energy storage capacity within the available volume.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Power

If multiple single cells are stacked, then the voltage and capacity are improved, but the vulnerability to environmental factors increases

Engineering Contradiction:

Improvevoltage and capacityVSAvoidenvironmental factor vulnerability

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

Multiple single cells are nested within a protective outer container that provides a barrier against environmental factors such as moisture, oxygen, and physical damage. This nested structure allows the battery to achieve high voltage and capacity through stacking while the outer container protects the entire assembly from harmful environmental conditions.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 design enhances the electrochemical cell's reliability by maintaining electrical connection integrity, reducing the risk of displacement and external force damage, while allowing for increased capacity and voltage through parallel or series connections, and protecting the cells from environmental factors.

Implementation Method 1

a welded portion in which the first inner container and the second inner container are welded to each other

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

utilizing materials like polyethylene terephthalate and ultrasonic welding for enhanced reliability

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS11764443B2Electrochemical cell

Publication Date: 2023.09.19 KYOCERA CORP

AI summary

An electrochemical cell includes a first single cell including a first power generation element and a first inner container which accommodates the first power generation element, a second single cell including a second power generation element and a second inner container which accommodates the second power generation element, and an outer container which accommodates the first single cell and the second single cell, and the first single cell and the second single cell are stacked, and the electrochemical cell includes at least one welded portion in which the first inner container and the second inner container are welded to each other.