Unit Battery Case-Terminal Structure for High-Density Pack Assembly
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Solution Overview
Problem
Conventional battery structures, such as cylindrical, pouch-shaped, and prismatic batteries, face limitations in energy density, electrical resistance, and structural constraints when used in large-capacity battery modules or packs for energy storage systems and electric vehicles, leading to increased costs and safety concerns due to the need for additional connections and welding.
Innovation Solution
A unit battery design where the positive and negative electrode body portions serve as large-area electrode terminals on the outer surfaces of the cell case, eliminating the need for additional tabs and minimizing welding, thereby maximizing energy density and reducing electrical resistance while enabling efficient thermal conduction and simplifying the recycling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional cylindrical, pouch-shaped, or prismatic battery structures are used, then the battery can be manufactured with standard structures, but the energy density is reduced and additional connection parts are required
Solution Approach 1:
The patent merges the electrode terminals with the battery case structure itself. The positive electrode terminal is formed by a conductive plate that constitutes part of the case, and the negative electrode terminal is formed by another conductive plate that is also part of the case structure. This eliminates the need for separate terminal components and reduces the total number of parts while increasing the proportion of active materials.
Solution Approach 2:
The case structure serves multiple functions: it provides mechanical protection, structural support, and simultaneously acts as the electrode terminal for electrical connection. The conductive plates forming the case also serve as both structural elements and electrical terminals, reducing the need for additional dedicated terminal components.
2Ease of manufacture
If additional connection parts and welding are used to connect batteries in series or parallel, then the battery module can be assembled, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent extracts the terminal function from separate connection components and integrates it directly into the battery case structure. By forming the terminals as integral parts of the case, the need for additional connection parts and complex welding processes is eliminated, simplifying both the device structure and manufacturing process.
Solution Approach 2:
Instead of adding separate terminals to the battery structure, the patent inverts the approach by making the case itself the terminal. The conductive plates that form the case structure directly provide the electrical connection function, reversing the conventional approach where terminals are added components.
3Quantity of substance
If conventional battery structures with protruding terminals are used, then electrical connection is achieved, but the energy density is reduced due to additional parts and occupied space
Solution Approach 1:
The patent combines the structural case with the electrical terminal function. The conductive plates forming the case are directly connected to the electrodes internally, providing electrical connection without requiring separate protruding terminals. This merging increases the proportion of active materials while maintaining ease of electrical connection.
4Reliability
If welding and additional connection parts are required, then battery modules can be assembled, but the cost increases and safety concerns arise
Solution Approach 1:
The patent removes the need for welding and additional connection parts by integrating the terminal function into the case structure. This elimination of separate connection components and welding processes reduces manufacturing cost and potential safety issues associated with welding operations.
Solution Approach 2:
The patent converts the potential harm of welding (safety risks, cost, complexity) into a benefit by using mechanical assembly of conductive plate structures. The conductive plates are designed to provide electrical connection through their structural arrangement, eliminating the need for thermal processes and reducing safety concerns.
Data Source
AI summary
Disclosed is a unit battery for manufacture of battery modules or battery packs, the unit battery including an electrode assembly mounted in a cell case, the electrode assembly being capable of being reversibly charged and discharged, a positive electrode body portion, to which a positive electrode of the electrode assembly is connected, the positive electrode body portion being configured to serve as a positive electrode terminal for external connection while forming one surface of the cell case, a negative electrode body portion, to which a negative electrode of the electrode assembly is connected, the negative electrode body portion being configured to serve as a negative electrode terminal for external connection while forming the other surface of the cell case, and an insulation portion configured to electrically insulate the positive electrode body portion and the negative electrode body portion from each other.