Innovative housing concepts for large-format lithium-ion batteries

Motivation and procedure

Lithium-ion cells (LIZ) are used to store electrical energy in a variety of applications. The cell-internal components (electrodes, separators and electrolyte) are surrounded by a housing which is subject to various requirements. The interior of the cell must be protected from external influences (moisture, dirt, etc.) and the release of internal, partly toxic and flammable substances must be prevented. In addition, the cell housing must take over the cooling function, fulfil requirements with regard to module integration and be as inexpensive and easy to manufacture as possible. For a high specific energy of a LIZ, the largest possible ratio between the stored energy and the housing mass is also elementary. This can be achieved in particular by large-format housing concepts. The production and use of large-format LIZs are currently still associated with high challenges which are of a production and assembly nature as well as affecting the safety and cooling of the cell stack.

Research objectives

The goal of InnoCase is to research and develop innovative, large-format package concepts that combine the advantages of conventional package types, offer production advantages and enable higher energy density. The aim is to simplify cell assembly and improve module integrability in order to reduce LIZ production costs. The latter is made possible by material savings and optimized production processes.

Research and development

Optimized housing concept by reducing the housing mass, using cell-internal safety elements and improving the electrical and thermal properties of the housing structure. Reduction of production costs due to cell assembly (€/kWh) through simplified assembly processes elaboration of safety concepts for large cell types and development of a standard-compliant safety system Simplified module integration of the cells taking into account cooling and positioning requirements as well as contacting of the cells to the module by remote laser beam welding application of laser radiation when joining the electrode foil to reduce the required joining area.

Research and project partners

  • ElringKlinger AG
  • Futavis Ltd.
  • Manz AG
  • TRUMPF Group
  • RWTH Aachen University
  • TU Munich



Konstantin Sasse

Team Leader


+49 1515 7384868