Jelly Roll, Layer Cake or Popsicle Stick – The Evolution of Lithium-Ion Battery Shapes in EV's – Resource World Magazine - Resource World Magazine

There are different forms of Lithium-Ion batteries in use today, and two new sizes of batteries to be introduced in the next year. This article explores the three types: pouch cells, prismatic cells and cylindrical cells. A few of the advantages of that arise from these shapes are discussed. The introduction of the Blade Battery by BYD, the largest EV manufacturer in China may signal a new trend in the shape of batteries to come

There are different forms for Lithium-Ion batteries in use today.

Pouch Cells and Prismatic Cells – Layer Cake

Prismatic cells are made up of many positive and negative electrodes layers sandwiched together leaving more possibility for short circuit and inconsistency. The higher capacity makes it difficult to protect each cell from over charging and dissipating heat. This is the form of Lithium-Ion Battery Cell used by General Motors and Hyundai. Unfortunately, these cells have been linked to some battery fires and Elon Musk that cylindrical cells are superior for protection from overheating.

These cells are rolled up layers of the positive and negative cell sandwich. Reputedly more thermally stable than prismatic cells, and they have been Tesla’s choice for all its vehicles until recently. Tesla is currently leading the charge in terms of range, energy density and safety but that title may soon pass to another form as we shall discuss.

The current generation of cylindrical cells have dimensions of 21 millimetres long by 70 millimeters in...

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