Battery components

Abstract

Example battery components (108, 200, 306) for a battery (100, 300) are described herein. In an example, a battery component includes a plate member (202, 308) having at least two flanges (204) extending from an inner periphery (206) of the plate member (202, 308) to create two or more slots (208) in the plate member. The battery component also includes at least two arms (210, 310) converging from the inner periphery (206) of the plate member towards a center of the plate member. The at least two arms are positioned in the two or more slots (208) without being in contact with the at least two flanges (204). The at least two arms have a non-linear profile.

Description

BATTERY COMPONENTSBACKGROUND

[0001] Batteries, including cylindrical batteries, are commonly utilized as power sources in portable electronic devices, as well as in hybrid and electric vehicles. The efficiency and performance of the batteries are largely dependent on the design of various internal components, especially current collector plates, of the batteries. The current collector plates, also be known as cathode discs, are central to functionality of a battery, as the cathode discs are responsible for enabling the flow of electric current. In the context of the cylindrical batteries, the current collector plates are specifically designed to facilitate efficient energy transfer and to ensure the durability of the electrical connection over a course of the battery's life.BRIEF DESCRIPTION OF FIGURES

[0002] The detailed description is provided with reference to the accompanying figures, wherein:

[0003] FIG. 1 illustrates an exploded view of a battery, according to an example;

[0004] FIG. 2A illustrates a perspective view of a battery component of a battery, according to an example;

[0005] FIG. 2B illustrates a side view of the battery component of the battery, according to another example;

[0006] FIG. 3 illustrates a cross-sectional view of a battery, according to an example; and

[0007] FIG. 4 illustrates multiple graphs depicting characteristics of the battery component, according to another example.DETAILED DESCRIPTION

[0008] Generally, various components are employed in cylindrical batteries. One such component is current collector plates or cathode discs. The cathode discs are welded to an electrode assembly, such as a jelly roll, before inserting the electrode assembly in a casing of a battery. Once inserted inside the casing, a rivet is welded to the cathode disc. Existing cathode discs are designed to have a flat or shoulder tab structure that connects a cathode electrode to a terminal (which is the rivet) of the battery. While the flat cathode disc performs the function of providing the electrical connectivity between the cathode electrode and the rivet, the existing cathode discs pose challenges during assembly of the battery if there are dimensional discrepancies among other components. To address this, the industry has come up with a flexible cathode disc which facilitates the assembly of the cell components. The flexible cathode discs include a frame member to which multiple flanges are connected in a stepped manner. Such an arrangement may make the existing cathode discs are frail in nature and hence may not be able to provide adequate structural support to withstand mechanical stresses during battery operation, such as expansion and contraction of electrodes. This may result in deformation or failure of the current collector plates over time. Any damage to the cathode discs may disturb tolerances and create challenges during the welding process and may result in poor electrical connections and increased resistance within the battery.

[0009] Additionally, in the existing cathode discs, when the rivet is welded to the cathode disc, a surface contact between a shoulder tab structure of the cathode disc and the rivet is often improper. This may result in sub-optimal electrical connections and increased resistance at a weld interface.

[0010] Furthermore, the existing cathode disc designs may exhibit poor direct current internal resistance (DCIR) performance when the batteryis being charged or discharged. DCIR is a measure of the internal resistance of the battery and is a determinant of the efficiency and power capability of the battery. Thus, high DCIR values in the cell may lead to increased heat generation, reduced energy efficiency, and faster degradation of the battery over time. The exiting cathode discs may also provide inadequate infiltration of electrolytes. As the electrolytes are responsible for ionic conductivity between the cathode and anode, poor infiltration may lead to uneven ion distribution. This may further aggravate the problem of high DCIR.

[0011] The present subject matter describes example battery components and batteries having such a battery component. The present subject matter seeks to address the issues associated with the existing battery components by providing an innovative design of a battery component that may enhance electrical contact, structural integrity, thermal management, design flexibility, manufacturing simplicity, space efficiency, and ease of assembly.

[0012] In accordance with the present subject matter, a battery component, such as a current collector plate, for being connected to an electrode assembly of a battery is described. The battery component includes a plate member having at least two flanges extending from an inner periphery of the plate member. The at least two flanges may create two or more slots in the plate member.

[0013] In addition, the battery component includes at least two arms converging from the inner periphery of the plate member towards a center of the plate member. The at least two arms are positioned in the two or more slots without being in contact with the at least two flanges. In a preferred example, the at least two arms have a non-linear profile.

[0014] According to the present subject matter, the flanges may improve the electrical connection between the battery component and the electrode assembly, thereby leading to more efficient current collection and distribution. Further, the presence of the at least two flanges may provideadditional structural support to the battery component. This may enhance the durability and longevity of the current collector plate, especially under the mechanical stresses encountered during battery operation. In addition, the design of the arms and flanges may facilitate better heat dissipation.

[0015] The present subject matter is further described with reference to the accompanying figures. Wherever possible, the same reference numerals are used in the figures and the following description to refer to the same or similar parts. It should be noted that the description and figures merely illustrate principles of the present subject matter. It is thus understood that various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.

[0016] The manner in which the present subject matter is implemented are explained in detail with respect to FIGS. 1 -4. While aspects of described subject matter can be implemented in any number of different devices, environments, and / or implementations, the examples are described in the context of the following system(s). It is to be noted that drawings of the present subject matter shown here are for illustrative purposes and are not drawn to scale.

[0017] FIG. 1 illustrates an exploded view of a battery 100, such as a secondary battery, according to an example. The battery 100 includes a casing 102. The casing 102 may serve as an outer enclosure and structural support for internal components of the battery 100. The casing 102 may be made of a conductive metal, e.g., aluminum, an aluminum alloy or nickel- coated steel, to provide mechanical protection and electrical conductivity. The casing 102 as depicted in FIG. 1 is formed in a cylindrical shape having a side wall 102a of a predetermined diameter. The material and thickness of the casing 102 may be selected based on factors such as strength,thermal conductivity, and compatibility with a chemistry of the battery 100. The casing 102 has a closed end 104 and an open end (not shown).

[0018] The battery 100 further includes an electrode assembly 106, such as a jelly roll. The electrode assembly 106 in a cylindrical battery may refer to a coiled structure having alternating layers of a first electrode or anode (not shown) and a second electrode, or a cathode (not shown) separated by a separator layer (not shown) interposed between the first electrode and the second electrode. Thereafter, the first electrode, the separator layer, and the second electrode are tightly wound to fit within the casing 102. The anode and the cathode are typically in the form of thin sheets or foils in which the active material, such as anode material and cathode material are coated, and the separator layer is a porous, electrically insulating material that allows ions to pass through while preventing direct contact between the anode and the cathode, which would cause a short circuit.

[0019] The electrode assembly 106 is thereafter electrically connected to a battery component 108, such as a current collector plate, at one end. The battery component 108 may act as a bridging component to collect electrical current generated at the electrode assembly 106 and connect with an external terminal. In the present subject matter, the battery component 108 is connected to an uncoated portion of the positive electrode, such as an electrode foil. The battery component 108 features a distinctive plus-shaped pattern with non-linear arms that extend outwards from a central area. The design of the battery component 108 of the present subject matter may improve mechanical stability and enhance electrical performance of the battery 100. In addition, the arms may exhibit a wave spring structure to accommodate variations in height of the electrode assembly 106 thereby ensuring consistent contact and reducing the risk of mechanical failure. For example, when the battery component 108 is attached to the electrode assembly 106, the non-linear profile of the armsensures the compression or expansion of the battery component 108 with minimal arm movement. The design of the battery component 108 as per the present subject matter may minimize the space needed for the battery component 108 while simultaneously enhancing rigidity.

[0020] Details with respect to the battery component 108 are provided in detail in conjunction with FIGS. 2 to 4. Although the battery component 108 is depicted in FIG. 1 as a cathode plate, it may be understood that the battery component 108 may be implemented as an anode plate or both as a cathode plate and an anode plate.

[0021] In addition, an insulating disc or a gasket 1 10 is mounted on the battery component 108, before the electrode assembly 106 is inserted inside the casing 102 through the open end. The insulating disc 1 10 is therefore disposed between the battery component 108 and an inner surface of the closed end 104 of the casing 102. Further, the open end of the casing 102 is closed with a bottom plate 1 12 to hold the electrode assembly 106 in the casing 102. The bottom plate 1 12 is attached with the casing 102 in such a manner that the bottom plate 1 12 is in contact with the negative electrode of the electrode assembly 106. As a circumferential edge of the bottom plate 1 12 is aligned with the side wall 102a of the casing 102, the casing 102 and in turn a top surface of the closed end 104 acts as a negative terminal of the battery 100. The bottom plate 1 12 is further sealed with the casing 102 by a sealing rubber 1 14 and a closing pin 1 16.

[0022] In addition, the battery 100 includes a rivet 1 18 attached to the closed end 104 of the casing 102 through a rivet gasket 120. The rivet 118 is welded to the battery component 108. As a result, the rivet 1 18 acts as a positive terminal of the battery 100. The rivet gasket 120 provides a hermetic sealing between the rivet 118 and the closed end 104 of the casing 102. The rivet gasket 120 provides electrical insulation between opposite terminals of the battery 100. As may be appreciated, the battery component 108 may provide a shorter current flow path through the rivet 1 18. Thus, thebattery component 108 may help to lower the internal resistance of the battery 100 which may improve charging and discharging efficiency of the battery 100.

[0023] FIG. 2A and FIG. 2B illustrate a perspective view 200A and a side view 200B of a battery component 200, in accordance with an example. Although the battery component 200 as depicted in FIGS. 2A and 2B has a substantially circular shape, the battery component 200 may have any suitable shape based on a shape of an electrode assembly on which the battery component 200 is to be mounted. The battery component 200 is similar to the battery component 108.

[0024] In an implementation, the battery component 200 may be employed as a current collector plate. The battery component 200 includes a plate member 202 that defines a base of the battery component 200. The plate member 202 may be a flat, conductive plate that forms a primary electrical connection between the electrode assembly and an external circuit of the battery. In an example, the plate member 202 may be made from a conductive material, such as copper, aluminum, or a coated metal to offer low electrical resistance and good thermal conductivity. The plate member 202 includes at least two flanges 204 that extend from an inner periphery 206 of the plate member 202 towards a center of the plate member 202. As is evident from FIG. 2A, the at least two flanges 204 are integral to the plate member 202 and have a variable width.

[0025] In addition, the at least two flanges 204 divide an inner area of the plate member 202 to create two or more slots 208 in the plate member 202. In an example, the two or more slots 208 allows for efficient electrolyte infiltration ensuring that electrolytes can easily access active materials within the electrode assembly, which is paramount for ionic conductivity and battery performance. In addition, the two or more slots 208 may provide space to accommodate the physical expansion of the electrode assembly during charging and discharging cycles of the battery. As a result, the twoor more slots 208 mitigate mechanical stress and potential damage to the electrode assembly. As is evident from FIG. 2B, in the battery component 200, a plane of the plate member 202 is same as the plane of the at least two flanges 204. The co-planarity of the plate member 202 with the flanges 204 ensures a uniform and consistent thickness across the battery component 200. This also facilitates in maintaining structural integrity and uniform current distribution.

[0026] Further, the battery component 200 includes at least two arms 210 such that the at least two arms 210 are arranged radially on the plate member 202. The at least two arms 210 converge from the inner periphery 206 of the plate member 202 towards a center of the plate member 202. As can be seen in FIG. 2A, each arm 210 has a varying width. For example, a portion of the arm 210 proximal to the inner periphery 206 of the plate member 202 has a width of about 7.7 mm. On the other hand, a portion of the arm 210 distal from the inner periphery 206 and proximal to the center of the plate member 202 has a width of about 4.2 mm. In addition, each arm 210 may have a length of about 10 mm.

[0027] It will be evident to a person skilled in the art that the number of arms correspond to the number of slots in the plate member 202. In the present subject matter, the at least two arms 210 are positioned in the two or more slots 208 without being in contact with the at least two flanges 204 of the plate member 202. In the battery component 200 of the present subject matter, the at least two arms 210 have a non-linear profile such that a portion of each of the at least two arms 210 is in contact with an electrode assembly, such as the electrode assembly 106. The non-linear profile of the at least two arms 210 facilitates the at least two arms 210 to exhibit a wave spring action. Such an action allows the arms 210 to flexibly accommodate variations in the height of the electrode assembly, such as the jelly roll within the battery. This may reduce the likelihood of mechanical fatigue and failureat the contact points, thereby enhancing the overall durability and longevity of the battery.

[0028] In an implementation, the non-linear profile of the at least two arms 210 includes an S-shaped profile or a wave-like profile. In an example, the non-linear profile of the at least two arms 210 may include a trough 212 and a crest 214 profile, as depicted in FIG. 2B. The mechanical contact ensures that contact resistance between the battery component 200 and the electrode assembly is reduced.

[0029] Further, in the present subject matter, the at least two arms 210 are in a plane different from the plane in which the plate member 202 lies. For example, as may be seen from FIG. 2B, a plane of the plate member 202 is lower than a plane of the at least two arms 210. Different planes of the arms 210 and the plate member 202 may lead to even distribution of mechanical stress across the battery component 200. This may help to minimize localized stress concentrations which could otherwise lead to mechanical fatigue or failure. In addition, having the arms 210 and the plate member 202 at different places may improve thermal management within the battery. For example, heat generated during operation may be effectively dissipated, reducing the risk of overheating and improving the battery’s thermal stability.

[0030] The battery component 200 also includes a protruding member 216 formed about the center of the plate member 202. In an example, the protruding member 216 fits under a hollow rivet of a battery, such as the battery 100. In an example, each of the two or more arms 210 are in a plane different from the plane in which the protruding member 216 lies. As is evident from FIG. 2B, the plane of the two or more arms 210 is below the plane of the protruding member 216. Thus, the plate member 202, the two or more arms 210, and the protruding member 216 all lie in different planes with respect to each other. Further, as the flanges 204 are in the same plane of the plate member 202, and the arms 210 extend directly fromthe plate member 202 to the protruding member 216 in the center of the cathode disc or the battery component 108, the internal resistance of the battery is decreased.

[0031] The above-described structure of the battery component 200 allows the at least two arms 210 to expand and compress radially with respect to an electrode assembly with which the battery component 200 is attached. While mounting the battery component 200 on the electrode assembly, the plate member 202 and the two or more flanges 204 are attached or welded to an uncoated portion of the electrode assembly. This increases a surface contact between the electrode assembly and the battery component 200. The increase in the surface contact may facilitate in reduction in the internal resistance of the battery. In an example, a battery component made as per the present subject matter is welded to an uncoated portion of the cathode foil and an anode current collector plate is welded to an uncoated portion of the anode foil.

[0032] For example, when the height of the electrode assembly is more than desired, when the electrode assembly is welded to the two or more flanges 204, the at least two arms 210 may get stretched in an upward direction. Such a movement of the at least two arms 210 with respect to the plate member 202 is possible due to the different planes of the arms 210 and the plate member 202. Moreover, due to different planes of the plate member 202 and the arms 210, any application of force at the protruding member 216 may not have any impact over the weld area (i.e., the plate member 202 and the two or more flanges 204).

[0033] FIG. 3 illustrates a cross-sectional view of a battery 300, according to an example. The battery 300 includes an outer casing 302, which serves as the structural enclosure for the internal components of the battery 300. The outer casing 302 is similar to the casing 102. The battery 300 further includes an electrode assembly 304 accommodated within the outer casing 302. The electrode assembly 304 is similar to the electrodeassembly 106. As explained with respect to FIG. 1 , the electrode assembly 304 may be a jelly roll that includes active materials of the battery 300, including the cathode, anode, and separator, which are wound together in a jelly roll configuration.

[0034] The battery 300 may include a battery component 306 such as a current collector plate welded to the electrode assembly 304. As described above, the battery component 306 includes a plate member 308 having an outer diameter of about 41 millimetres (mm). The plate member 308 is similar to the plate member 202 and acts as a base of the battery component 306. In the present implementation, the battery component 306 being used as a current collector plate has a thickness of about 0.4 millimetres (mm). In addition, the battery component 306 may have a height of about 1.9 mm. Further, the battery component 306 may be made of an aluminium material, a stainless-steel material, or a copper material.

[0035] Further, the battery component 306 includes at least two arms 310 connected to an inner periphery of the plate member 308. The at least two arms 310 are similar to the at least two arms 210. The at least two arms 310 have a non-linear profile to exhibit wave spring action. Further, the battery component 306 may include a protruding member 312, similar to the protruding member 216, formed about a center of the plate member 308.

[0036] Upon assembly of the battery 300, the protruding member 312 comes into contact with a rivet 314. The rivet 314 may be positioned at the top of the battery 300. The rivet 314 may ensure that an internal environment of the battery 300 is hermetically sealed from external contaminants and moisture. As mentioned above, the battery component 306 is placed beneath the rivet 314 such that the protruding member 312 is in contact with the rivet 314. As a result, the battery 300 employing the battery component 306 provides a direct surface connection between the electrode assembly 304 and the rivet faces. By shortening the current flow path length between the rivet 314 and contact face of the electrodeassembly 304, the battery component 306 may cause a reduction in electrical resistance.

[0037] FIG. 4 illustrates multiple graphs 400A, 400B, and 400C depicting characteristics of the battery component, according to another example. For example, the graphs 400A, 400B, and 400C collectively compare performance metrics of an existing battery component 402, such as a cathode disc, with the battery component 404 of the present subject matter, in terms of discharge capacity, thermal management, and capacity retention.

[0038] Graph 400A depicts a discharge capacity, measured in ampere-hours (Ah), against different discharge rates, expressed in terms of C-rate (C). The discharge capacity of a battery may represent the maximum amount of energy that the battery may deliver under certain specified conditions. As is evident from graph 400A, the battery component 404 maintains a higher discharge capacity across all tested discharge rates when compared to the battery component 402. This indicates that the battery component 404 is more efficient in delivering energy, particularly at higher discharge rates, which is a desirable attribute for applications requiring high power output.

[0039] Graph 400B illustrates the temperature rise, measured in degrees Celsius (°C), as a function of the discharge rate (C). The graph 400B reveals that the battery component 404 results in a lower temperature rise at higher discharge rates compared to the battery component 402. The reduced temperature rise suggests that the battery component 404 of the present subject matter offers improved thermal management, which is beneficial for maintaining the structural integrity and longevity of the battery, as well as ensuring safety during operation.

[0040] Graph 400C depicts the capacity retention, expressed as a percentage (%), against the discharge rate (C). The graph 400C shows that the design of the battery component 404 facilitates in retaining a higherpercentage of its capacity across the range of discharge rates tested. This superior capacity retention is indicative of the ability of the battery component 404 to sustain performance over the course of the battery's operational life, which is particularly valuable for applications where long- term reliability is paramount.

[0041] Although aspects for the present disclosure have been described in a language specific to structural features and / or methods, it is to be understood that the appended claims are not limited to the specific features or methods described herein. Rather, the specific features and methods are disclosed as examples of the present disclosure.

Claims

I / We Claim:1 . A battery component (108, 200, 306) for being connected to an electrode assembly (106, 304) of a battery (100, 300), the battery component (108, 200, 306) comprising: a plate member (202, 308) having at least two flanges (204) extending from an inner periphery (206) of the plate member (202, 308) to create two or more slots (208) in the plate member (202, 308); and at least two arms (210, 310) converging from the inner periphery (206) of the plate member (202, 308) towards a center of the plate member (202, 308) and positioned in the two or more slots (208) without being in contact with the at least two flanges (204), wherein the at least two arms (210, 310) have a non-linear profile.

2. The battery component (108, 200, 306) as claimed in claim 1 , wherein the non-linear profile of the at least two arms (210, 310) comprise a trough (212) and a crest (214) profile.

3. The battery component (108, 200, 306) as claimed in claim 1 , wherein the non-linear profile of the at least two arms (210, 310) comprise an ‘S’ shaped profile or wave-like profile.

4. The battery component (108, 200, 306) as claimed in claim 1 , wherein the at least two arms (210, 310) are in a plane different from the plane in which the plate member (202, 308) lies.

5. The battery component (108, 200, 306) as claimed in claim 4, wherein a plane of the plate member (202, 308) is lower than a plane of the at least two arms (210, 310).

6. The battery component (108, 200, 306) as claimed in claim 1 , wherein a plane of the plate member (202, 308) is same as the plane of the at least two flanges (204).

7. The battery component (108, 200, 306) as claimed in claim 1 , wherein the at least two arms (210, 310) are arranged radially on the plate member (202, 308).

8. The battery component (108, 200, 306) as claimed in claim 1 , wherein the at least two flanges (204) have variable width.

9. The battery component (108, 200, 306) as claimed in claim 1 , wherein the battery component (108, 200, 306) comprises a protruding member (216, 312) formed about the center of the plate member (202, 308).

10. A battery (100, 300) comprising: a casing (102, 302); an electrode assembly (106, 304) comprising at least a positive electrode and a negative electrode, the electrode assembly (106, 304) is positioned within the casing (102, 302); and a battery component (108, 200, 306) connected to one of the positive electrode and the negative electrode, wherein the battery component (108, 200, 306) comprises: a plate member (202, 308) having at least two flanges (204) extending from an inner periphery (206) of the plate member (202, 308) to create two or more slots (208) in the plate member (202, 308); and at least two arms (210, 310) converging from the inner periphery (206) of the plate member (202, 308) towards a center of the plate member (202, 308) and positioned in the two or more slots(208) without being in contact with the at least two flanges (204), the at least two arms (210, 310) have a non-linear profile.1 1. The battery (100, 300) as claimed in claim 10, wherein the non-linear profile of the at least two arms (210, 310) comprise a trough (212) and a crest (214) profile.

12. The battery (100, 300) as claimed in claim 10, wherein the non-linear profile of the at least two arms (210, 310) comprise an ‘S’ shaped profile or wave-like profile.

13. The battery (100, 300) as claimed in claim 10, wherein the at least two arms (210, 310) are in a plane different from the plane in which the plate member (202, 308) lies.

14. The battery (100, 300) as claimed in claim 13, wherein a plane of the plate member (202, 308) is lower than a plane of the at least two arms (210, 310).

15. The battery (100, 300) as claimed in claim 10, wherein a plane of the plate member (202, 308) is same as the plane of the at least two flanges (204).

16. The battery (100, 300) as claimed in claim 10, wherein the at least two arms (210, 310) are arranged radially on the plate member (202, 308).

17. The battery (100, 300) as claimed in claim 10, wherein the at least two flanges (204) have variable width.

18. The battery (100, 300) as claimed in claim 10, wherein the battery component (108, 200, 306) comprises a protruding member (216, 312) formed about the center of the plate member (202, 308).

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