Future-Proof Pouch Cell Design

Intro

Sodium-Ion (Na-Ion) batteries are essential for the future of energy storage, offering a sustainable alternative to Lithium-Ion cells. To fully unlock their potential, flexibility in cell design is critical, allowing them to adapt to a variety of applications. 

Pouch cells, with their space-saving design and ability to mold to different shapes and sizes, provide the flexibility and space-efficiency that Na-Ion cells need.  

Pouch cells are well known since many years; however, to scale production, the main challenge lies in ensuring leak-proofing and long-term durability. Clarios is therefore seeking innovative solutions & partners to tackle these challenges for Na-Ion pouch cells. 

Aimed for solution 

The main goal of this challenge is to enhance the durability and leak-proof performance of Na-Ion pouch cells. Clarios is looking for innovative improvements in two focus areas. Solutions may focus on individual aspects or offer holistic approaches. 

1. Sealing Technologies: Ensure long-term sealing integrity, particularly around the tab areas, to prevent leaks and maintain durability over a lifespan of 15+ years. 

• What sealing methods can best ensure long-term integrity, especially in high-stress areas like the tabs? 
• Can traditional heat sealing be further optimized, or are alternative methods (e.g., ultrasonic sealing or adhesives) more cost-effective and durable? 
• What novel methods exist, that reduce the time of testing for leak-proofability in pouch cells without damaging the product?

2. Material Innovations: Explore advanced material choices for the pouch layers and sealing strips, ensuring compatibility with Na-Ion chemistry while balancing performance and cost-efficiency. Note: Aluminum is already the fixed material for tabs. 

• Which materials provide the best combination of flexibility, durability, and chemical compatibility with Na-Ion cells? 
• How can new materials improve sealing effectiveness without adding significant cost to the production process? 

No matter which innovative pathway you choose, it is crucial that the sealing solution withstand the harsh conditions of the electrolyte filling process and the temperature challenges in automotive applications.  
All details regarding criteria and requirements can be found in the tab “Criteria and guidelines”. 

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