Staggered Battery Cell Electrode Assembly for Space Utilization

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional battery cells with rectangular or cylindrical shapes face challenges in efficiently mounting in devices with various external structures, leading to reduced space utilization and capacity, especially in devices with curved portions.

Innovation Solution

A battery cell configuration with stacked electrode assemblies aligned vertically, where one side lower edge of an upper assembly contacts the top surface of a lower assembly, and one side upper edge of the lower assembly contacts the bottom surface of the upper assembly, allowing for a staggered structure that maximizes space utilization and accommodates diverse device shapes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional rectangular or cylindrical battery cells are used, then the battery cell structure is simple and easy to manufacture, but the space utilization in devices with various external structures is reduced

Engineering Contradiction:

Improvebattery cell manufacturing simplicityVSAvoidmounting adaptability to various device shapes

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The battery cell is divided into multiple electrode assemblies that are stacked in a staggered arrangement. Each electrode assembly can be independently manufactured using conventional methods, and then they are stacked together to form the final battery cell structure. This segmentation allows the battery to adapt to various device shapes while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs asymmetric stacking of electrode assemblies where adjacent assemblies are offset from each other in a staggered pattern. This asymmetric arrangement creates a compact overall shape that better conforms to device contours, improving space utilization while each individual assembly remains symmetric and easy to manufacture.

Inventive Principle:

Principle #4Asymmetry

2Adaptability or versatility

If electrode assemblies are stacked in a staggered array structure, then space utilization in devices is maximized, but the battery cell structure becomes more complex

Engineering Contradiction:

Improvespace utilization in various device spacesVSAvoidbattery cell structural complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrode assemblies are nested within a battery case that has an internal shape corresponding to the external shape of the stacked assemblies. This nesting approach allows the complex staggered structure to be contained within a simple outer case, reducing the perceived structural complexity while maintaining the space-efficient internal arrangement.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If electrode assemblies are stacked with aligned terminals vertically, then electrical connection is simplified, but the mounting flexibility in various device spaces is reduced

Engineering Contradiction:

Improveelectrode terminal alignment simplicityVSAvoidbattery cell volume efficiency

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The patent aligns electrode terminals in the vertical direction while stacking assemblies in a staggered horizontal arrangement. This use of vertical alignment provides a simple dimensional solution for electrical connections, while the horizontal staggering optimizes volume efficiency. The vertical dimension handles the electrical connection requirement, freeing the horizontal dimensions for space optimization.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS10319952B2Battery cell having electrode assembly of staggered array structure

Publication Date: 2019.06.11 LG ENERGY SOLUTION LTD

AI summary

Disclosed herein is a battery cell configured to have a structure in which two or more electrode assemblies, each including positive electrodes, negative electrodes, and separators disposed respectively between the positive electrodes and the negative electrodes, are mounted in a battery case, wherein the electrode assemblies are stacked such that electrode terminals of the electrode assemblies are aligned in a vertical direction, one side lower edge of an upper one of the electrode assemblies is disposed in contact with a top surface of a lower one of the electrode assemblies, and one side upper edge of the lower electrode assembly is disposed in contact with a bottom surface of the upper electrode assembly at an interface between the electrode assemblies, and the battery case has an internal shape corresponding to an external shape of the stacked electrode assemblies.