DESC:FORM 2

THE PATENTS ACT, 1970

(39 of 1970)

&

THE PATENT RULES, 2003

COMPLETE SPECIFICATION

[See Section 10 and Rule 13]

TITLE:

“A NOVEL PRISMATIC FORM FACTOR BASED BATTERY CELL”

APPLICANT:

E-TRNL ENERGY PRIVATE LIMITED
A company incorporated under the Indian Companies Act, 2013
having address at
Plot No. 08, SY No. 75, Sadaramangala lndustrial Area,
M.D. Pura White Field, Mahadevapura, Bengaluru,
Bengaluru urban, Pin Code – 560048, Karnataka, India

PREAMBLE TO THE DESCRIPTION:
The following specification particularly describes the invention and the manner in which it is to be performed:
FIELD OF THE INVENTION
The present invention relates to the field of battery cells. More particularly, the present invention relates to a novel prismatic design-based battery cell which allows high packing fraction for a battery pack, better thermal management, low production cost and cost complexity.

BACKGROUND OF THE INVENTION
Battery cells are available in multiple configurations, such as pouch, prismatic, and cylindrical shapes. The cells exhibit variations in their inner structure dimensions and the manufacturing methods applied to the electrode-separator-compound assembly. The selection of cell designs depends on factors such as optimizing packing efficiency, managing packaging considerations, addressing electrical, thermal, and mechanical engineering requirements of the battery pack, meeting performance specifications, and considering cost constraints.
Among the initial mass-produced cell varieties, one type remains prevalent in modern applications, i.e. cylindrical shaped cells in which the terminals located on opposite sides, often organized in multiple rows. The assembly of battery packs involves various methods such as spring loading, welding technology, adhesives, or wire-bonding. To secure cylindrical cells within a battery module or pack, rigid spacers, spacer strips, or mounting brackets are typically employed. Additionally, adhesive can be used as the primary means of affixing cylindrical cells, albeit at the cost of increased bulkiness and complexity in the battery pack.
Several challenges are posed by cylindrical cells in battery pack design. These challenges include the low packing density resulting from the circular cell cross-section, leading to the necessity of additional support and contactors in high-capacity batteries, thus increasing complexity and weight. Uniform thermal management and heat dissipation across all cells is found to be a significant challenge. Furthermore, thermal management issues get exacerbated by the concentration of current flow at the tabs and terminals, resulting in localized degradation of cells. A trade-off is necessitated by this issue between smaller cell formats, which are provided with superior thermal performance, and larger formats, which are associated with higher energy density and cost-efficiency.
Another cell variant, referred to as the pouch cell, was introduced, characterized by a sealed container composed of flexible multi-layer foil instead of a rigid outer can. Pouch cells often rely on cell frames as their primary means of fixation. In this configuration, cells are inserted, redundantly sealed, and maintained with loose tension. The interstitial spaces between these cells offer opportunities for additional applications, such as implementing a cooling system.
Pouch cells require protection from external impacts and punctures, limiting their suitability for use with machinery and in industrial settings. Additionally, pouch cells are prone to swelling, both reversible and irreversible, necessitating careful pack engineering to prevent cell pressurization and potential safety hazards. These cells can employ electrodes in either wound or stacked forms. Further, the stacked electrodes offer improved thermal engineering but come with higher manufacturing complexity and associated costs, sometimes raising safety concerns.
Another type of cell is prismatic cell includes a metallic or hard-plastic housing in a cuboid form. Prismatic cells come in two variations: single-row or two-row modules, with terminals located either on the top or bottom of the can. These cells are typically joined using various methods, including adhesive bonding with welding, the use of bus bars and support plates, or traction/form-fit connections through screwing or latching, with hole-bus bars acting as bridges. An alternative option for securing prismatic cells involves adhesive fixation, which demands a lightweight and flexible bonding medium to prevent the formation of air pockets.
The design and performance of battery cells, whether cylindrical or prismatic, is influenced by several key factors. The electrode and separator sheets located near the corners of the container may experience elevated stress levels, potentially resulting in faster degradation and safety concerns. Additionally, in the case of cuboid-shaped cells with metal casings, their high packing efficiency leads to densely packed battery packs, posing challenges for effective heat removal and thermal management, which can accelerate degradation and shorten their lifespan, especially in larger format cells. Furthermore, prismatic cells face thermal management issues similar to cylindrical cells, primarily due to the concentration of current at terminals and tabs. Lastly, the adoption of a stacking-type electrode design introduces significant manufacturing complexity into the process.
Several key factors affect battery cell design and production. These include lower packing density, which can impact energy storage capacity, thermal management challenges related to heat dissipation, increased production complexity, resulting in higher costs, difficulties in customizing cells to meet customer demands, and the complexity associated with achieving specific cell shapes.
CN110061168B discloses a cylindrical battery cell equipped with an insulating member (e.g., an insulating ring, one or more insulating layers integrated in a shaft of the cylindrical battery, etc.), and a battery module including the same. However, this invention has low packing density, low-level of thermal management and high production, cost complexity.
US10476044B2 discloses alkaline batteries or non-aqueous proton-conducting batteries in the form of a pouch-cell that is capable of cycling without the need for a safety vent thereby providing increased energy density and design flexibility of batteries. However, this invention has low packing density, low-level of thermal management and high production, cost complexity.
Therefore, due to above-mentioned drawbacks, there is a need of a prismatic battery cell that provides a high packing density within the battery pack, effective thermal regulation, and simplified production processes, leading to reduced manufacturing costs.

OBJECT OF THE INVENTION
The main object of the present invention is to have a novel prismatic form factor based battery cell which allows high packing fraction for a battery pack.
Another object of the present invention is to provide novel prismatic form factor based battery cell in which cell terminals are electrically separated by the shortest distance across the cell.
Yet another object of the present invention is to provide novel prismatic form factor based battery cell that has the faces with largest areas on opposite sides acting as the cell terminals
Yet another object of the present invention is to provide a novel prismatic form factor based battery cell that allows current to be spread over a large cross section area and hence prevent current concentration and hot spots.
Yet another object of the present invention is to provide a novel prismatic form factor based battery cell in which lower heating ensures that thermal management is unaffected by the close packing of cells in the battery pack.
Yet another object of the present invention is to provide a novel prismatic form factor based battery cell that eliminates the dependency of performance of a battery cell on the size and shape of the battery, thereby allowing cells with larger dimensions without compromising on the performance of the cell.
Yet another object of the present invention is to provide a novel prismatic form factor based battery cell that allows dimensional freedom, whereby cells can be made with any shape, not restricted to rectangular or circular.
Still another object of the present invention is to provide a novel prismatic form factor based battery cell with low manufacturing cost and complexity which improves the manufacturability of cells per kWH of battery.

SUMMARY OF THE INVENTION
The present invention relates to a novel prismatic form factor based battery cell which enables a high packing fraction within a battery pack, ensuring that the cell terminals are positioned at the shortest distance across the cell. Additionally, the present invention aims to minimize heating to maintain effective thermal management despite close cell packing within the battery pack.
In an embodiment, the present invention provides a novel prismatic form factor based battery cell. The novel prismatic form factor based battery cell comprises a body, a plurality of layers assembled inside the body. The body is a prismatic shaped body that provides a maximum flat face as a cell terminal as said prismatic shaped body reorients a flow of current. The body encompasses an anode layer, a separator layer, a cathode layer, an adhesion layer, an upper current collector layer and a lower current collector layer. The anode layer facilitates in a flow of a set of ions into the multi-dimensional electrode architecture based electrochemical cell and said anode layer includes a plurality of blind holes that increases the flow of the set of ions. The cathode layer provides a set of ions that allows for an intercalation in the anode layer. The separator layer facilitates a flow of both the set of ions between the anode layer and the cathode layer for preventing an issue of electric short circuit. The adhesion layer facilitates a set of electrical connections between the cathode layer and the upper current collector layer. The upper current collector layer and said lower current collector layer completes an electrical circuit of the multi-dimensional electrode architecture based electrochemical cell.
The above objects and advantages of the present invention will become apparent from the hereinafter set forth brief description of the drawings, detailed description of the invention, and claims appended herewith.

BRIEF DESCRIPTION OF THE DRAWING
An understanding of the novel prismatic form factor based battery cell of the present invention may be obtained by reference to the following novel prismatic form factor based battery cell drawing:
Figure 1(a) is a top view of novel prismatic form factor based battery cell according to an embodiment of the present invention;
Figure 1(b) is a side view of novel prismatic form factor based battery cell according to an embodiment of the present invention; and
Figure 1(c) is a perspective view of novel prismatic form factor based battery cell according to an embodiment of the present invention.
Figure 2 is an exploded view of novel prismatic form factor based battery cell according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described hereinafter with reference to the accompanying drawings in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough, and will fully convey the scope of the invention to those skilled in the art.
Many aspects of the invention can be better understood with references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings. Before explaining at least one embodiment of the invention, it is to be understood that the embodiments of the invention are not limited in their application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The embodiments of the invention are capable of being practiced and carried out in various ways. In addition, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
The present invention relates to a novel prismatic form factor based battery cell which enable a high packing fraction within a battery pack, ensure that the cell terminals are positioned at the shortest distance across the cell. Additionally, the present invention aims to minimize heating to maintain effective thermal management despite close cell packing within the battery pack.
In an embodiment, the present invention provides a novel prismatic form factor based battery cell. The novel prismatic form factor based battery cell comprises a body, a plurality of layers assembled inside the body. The body is a prismatic shaped body that provides a maximum flat face as a cell terminal as said prismatic shaped body reorients a flow of current. The body encompasses an anode layer, a separator layer, a cathode layer, an adhesion layer, an upper current collector layer and a lower current collector layer. The anode layer facilitates in a flow of a set of ions into the multi-dimensional electrode architecture based electrochemical cell and said anode layer includes a plurality of blind holes that increases the flow of the set of ions. The cathode layer provides a set of ions that allows for an intercalation in the anode layer. The separator layer facilitates a flow of both the set of ions between the anode layer and the cathode layer for preventing an issue of electric short circuit. The adhesion layer facilitates a set of electrical connections between the cathode layer and the upper current collector layer. The upper current collector layer and said lower current collector layer completes an electrical circuit of the multi-dimensional electrode architecture based electrochemical cell.
Figure 1(a) is a top view of novel prismatic form factor based battery cell according to an embodiment of the present invention. The novel prismatic form factor based battery cell (100) reorients the flow of current via a change in the construction or geometry and the prismatic shape provides large flat faces as cell terminals. Additionally, the length (denoted by X) of novel prismatic form factor based battery cell (100) ranges from 12mm to 400mm, width (denoted by Y) ranges from 12mm to 300m and thickness (denoted by Z) is in range from 5mm to 20mm, further the corner radius (denoted by R) is in range from 1mm to 99mm (depicted in Figure 1(c)). Further, The novel prismatic form factor based battery cell (100) comprises a body that is a prismatic shaped body that provides a maximum flat face (depicted as A in Figure 1(a)) as a cell terminal as said prismatic shaped body reorients a flow of current.
Figure 1(b) is a side view of prismatic electric cell according to an embodiment of the present invention. Furthermore, the prismatic shape of novel prismatic form factor based battery cell (100) permits a high packing fraction value for a battery pack and the cell terminals are separated by the shortest distance access the electric cell. Moreover, the large, flat faces of the cell terminals facilitate even distribution of current across the entire surface area, mitigating concerns related to current and heat concentration.
Figure 1(c) is a bottom view of novel prismatic form factor based battery cell according to an embodiment of the present invention. The lower heating characteristics of the novel prismatic form factor based battery cell (100) ensure that thermal management remains unaffected even when cells are closely packed within the battery pack. Furthermore, the prismatic shape allows large-format cells to demonstrate thermal management and power performance capabilities similar to those of smaller cells. Additionally, the prismatic shape contributes to reduced manufacturing costs and complexity, ultimately enhancing the manufacturability of cells per kilowatt-hour (kWh) of battery output.
The novel prismatic form factor based battery cell (100) has a stacked arrangement and further the prismatic electric cell comprise of a plurality of layer that includes a lower current collector layer, an anode layer, a separator layer, a cathode layer, an adhesion layer, and an upper current collector layer. The anode layer is placed above the lower current collector layer and the separator layer is positioned above the anode layer. Further, the cathode layer is placed over the separator layer. The separator layer facilitates a flow of lithium ions between the anode and cathode layers, thereby preventing electric short circuits. Additionally, the adhesion layer is applied to the upper surface of the cathode layer, and the conductive layer serves as the upper current collector, positioned atop the adhesion layer. The adhesion layer facilitates one or more electrical connections between the cathode layer and the upper current collector layer and further to complete the electrical circuit, a conductive component acts as the lower current collector, is affixed to the bottom surface of the anode layer. The arrangement of plurality of layers forms the multi-dimensional electrode cell.
Referring to Figure 2, an exploded view of the prismatic form factor based battery cell (100) is depicted. The prismatic form factor based battery cell (100) encompasses an anode layer (1), a separator layer (2), a cathode layer (3), an adhesion layer (5), an upper current collector layer (6) and a lower current collector layer (4). The anode layer (1) facilitates in a flow of a set of ions into the multi-dimensional electrode architecture based electrochemical cell (100) and said anode layer (1) includes a plurality of blind holes that increases the flow of the set of ions. The plurality of blind holes have a depth in range from 0.1 mm to 2 mm less than the height of said anode layer (1). An interior surface of the plurality of blind holes are coated with a separator material. The plurality of blind holes are filled with a pin-shaped cathode material. The plurality of blind holes ensures a movement of pin-shaped cathode material through the anode layer (1).
The pin-shaped cathode material is composed of a pre-defined amount of cathode active material powder that allows a transport of plurality of ions, without a change in a kinetic value.
The cathode layer (3) provides a set of ions that allows for an intercalation in the anode layer (1). The separator layer (2) facilitates a flow of both the set of ions between the anode layer (1) and the cathode layer (3) for preventing an issue of electric short circuit.
The separator layer (2) is sandwiched between the cathode layer (3) and the anode layer (1). The separator layer (2) have a thickness in range from 5 to 150 microns. The separator layer (2) is composed of a ceramic powder.
The adhesion layer (4) facilitates a set of electrical connections between the cathode layer (3) and the upper current collector layer (5). The upper current collector layer (5) and said lower current collector layer (6) completes an electrical circuit of the multi-dimensional electrode architecture based electrochemical cell (100). The upper current collector layer (5) is affixed on an upper surface of the adhesion layer (4). The lower current collector layer (6) is affixed on a bottom surface of the anode layer (1).
The adhesion layer (4) is sandwiched between the cathode layer (3) and the upper current collector layer (5).
The anode layer (1), the separator layer (2), the cathode layer (3), the upper current collector layer (5), the adhesion layer (4), and the lower current collector layer (6) are affixed to each other via at least one of a mechanical contact process and a deposition process.

EXAMPLE 1
Experimental Analysis
The present invention provides a novel prismatic form factor based battery cell on which there is an increase of 7% to 10%, as in a conventional cell, the active energy storage material accounts for only 59% of the cell volume, while the inactive components (electrolyte, separator, binders, conductive additives, current collectors etc. account for the rest. In the present invention, due to the elimination of the current collector films, the volume occupied by the active materials increase to 65%, or a 7% to 10% increase in packing efficiency.
Further, the shortest distance by which the terminals are separated across the cell may range from 7mm to 20 mm.
Further, electrical heat generation is reduced by 90% as compared to conventional cells. Further, fast charging time is lowered to 12 minutes (0-80%). Also, temperature rise from fast charging reduce from 16-25°C (as observed in case of conventional cells) to 2-3°. Additionally, fire safety is improved substantially with the structure of the present invention with temperature stability of cell (temperature at which cell spontaneously catches fire) increasing and cells not go into thermal runaway (due to stable nature of ceramic separators).
Therefore, the present invention provides a novel prismatic form factor based battery cell which enable a high packing fraction within a battery pack, ensure that the cell terminals are positioned at the shortest distance across the cell. Additionally, the heating is minimized to maintain effective thermal management despite close cell packing within the battery pack.
Many modifications and other embodiments of the invention set forth herein will readily occur to one skilled in the art to which the invention pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
The foregoing description of embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principals of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
,CLAIMS:CLAIMS

We claim:
1. A prismatic form factor based battery cell (100), comprising:
a body;
a plurality of layers assembled inside the body;
wherein,
said body is a prismatic shaped body that provides a maximum flat face as a cell terminal as said prismatic shaped body reorients a flow of current;
said body encompasses an anode layer (1), a separator layer (2), a cathode layer (3), an adhesion layer (5), an upper current collector layer (6) and a lower current collector layer (4);
said anode layer (1) facilitates in a flow of a set of ions into the multi-dimensional electrode architecture based electrochemical cell (100) and said anode layer (1) includes a plurality of blind holes that increases the flow of the set of ions;
said cathode layer (3) provides a set of ions that allows for an intercalation in the anode layer (1);
said separator layer (2) facilitates a flow of both the set of ions between the anode layer (1) and the cathode layer (3) for preventing an issue of electric short circuit;
said adhesion layer (4) facilitates a set of electrical connections between the cathode layer (3) and the upper current collector layer (5); and
said upper current collector layer (5) and said lower current collector layer (6) completes an electrical circuit of the multi-dimensional electrode architecture based electrochemical cell (100).
2. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said prismatic form factor based battery cell (100) have length in range from 12mm to 400mm, width in range from 12mm to 300m and thickness in range from 5mm to 20mm, with a corner radius in range from 1mm to 99mm.
3. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said cell terminals are separated by a pre-defined distance across the prismatic form factor based battery cell (100).
4. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said anode layer (1), the separator layer (2), the cathode layer (3), the upper current collector layer (5), the adhesion layer (4), and the lower current collector layer (6) are affixed to each other via at least one of a mechanical contact process and a deposition process.
5. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said plurality of blind holes have a depth in range from 0.1 mm to 2 mm less than the height of anode layer (1).
6. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein an interior surface of the plurality of blind holes are coated with a separator material.
7. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said plurality of blind holes are filled with a pin-shaped cathode material.
8. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said plurality of blind holes ensures a movement of pin-shaped cathode material through the anode layer (1).
9. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said pin-shaped cathode material is composed of a pre-defined amount of cathode active material powder, that allows a transport of plurality of ions, without a change in a kinetic value.
10. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said separator layer (2) is sandwiched between the cathode layer (3) and the anode layer (1).
11. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said separator layer (2) have a thickness in range from 5 to 150 microns.
12. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said separator layer (2) is composed of a ceramic powder.
13. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said adhesion layer (4) is sandwiched between the cathode layer (3) and the upper current collector layer (5).
14. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said upper current collector layer (5) is affixed on an upper surface of the adhesion layer (4).
15. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said lower current collector layer (6) is affixed on a bottom surface of the anode layer (1).
16. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said multi-dimensional electrode architecture based electrochemical cell (100) achieves an increase in an energy density in range from 25% to 33%.
17. The prismatic form factor based battery cell (100) as claimed in claim 1, wherein said anode layer (1), separator layer (2), a cathode layer (3), adhesion layer (5), a upper current collector layer (6) and said lower current collector layer (4) are in form of a flat contact surfaces.
18. The prismatic form factor based battery cell (100) as claimed in claim 17, wherein said flat contact surfaces provides a high packing fraction value for the battery cell.