Angled Battery Current Collector With Tapered Cross-Section

Solution Overview

Problem

Current collectors in battery cells face limitations in terms of dimension constraints, resistance, and potential for localized heating due to non-uniform cross-sectional areas, which can lead to increased weight and risk of damage.

Innovation Solution

A current collector with a first section connected to an electrode assembly and a second section angled relative to the first, featuring a decreasing cross-sectional area along the current path to minimize resistance and prevent localized heating, allowing flexible terminal placement while maintaining efficient energy transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If the current collector is made thinner to reduce weight, then weight is reduced, but resistance increases

Engineering Contradiction:

Improveweight of current collectorVSAvoidelectrical resistance

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The current collector employs varying thickness along its length, with the thickest section at the electrode assembly connection point and progressively thinner sections toward the terminal. This local quality variation optimizes both weight and resistance: thicker sections where current density is highest minimize resistance, while thinner sections reduce overall weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention changes the geometric parameter of thickness along the current collector's length. By continuously or stepwise varying the thickness parameter from the electrode assembly end to the terminal end, the design achieves optimal balance between electrical resistance and weight, rather than using a uniform thickness throughout.

Inventive Principle:

Principle #35Parameter changes

2Weight of moving object

If the current collector has non-uniform cross-sectional area, then weight is reduced, but localized heating increases

Engineering Contradiction:

Improveweight of current collectorVSAvoidlocalized heating

Core Design Contradiction:

Weight of moving objectVSTemperature

Solution Approach 1:

The current collector employs varying thickness along its length, with the thickest section at the electrode assembly connection point and progressively thinner sections toward the terminal. This local quality variation optimizes both weight and resistance: thicker sections where current density is highest minimize resistance, while thinner sections reduce overall weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention changes the geometric parameter of thickness along the current collector's length. By continuously or stepwise varying the thickness parameter from the electrode assembly end to the terminal end, the design achieves optimal balance between electrical resistance and weight, rather than using a uniform thickness throughout.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If the terminal is placed at a distant location for flexible configuration, then adaptability is improved, but current path length increases leading to higher resistance

Engineering Contradiction:

Improveterminal placement flexibilityVSAvoidelectrical resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The current collector employs varying thickness along its length, with the thickest section at the electrode assembly connection point and progressively thinner sections toward the terminal. This local quality variation optimizes both weight and resistance: thicker sections where current density is highest minimize resistance, while thinner sections reduce overall weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The current collector features an asymmetric cross-sectional profile along its length, with the maximum thickness at the electrode assembly end and decreasing thickness toward the terminal. This asymmetric design allows the collector to accommodate long current paths for flexible terminal placement while minimizing resistance through optimized material distribution.

Inventive Principle:

Principle #4Asymmetry

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution reduces resistance, minimizes weight, and prevents localized heating, enhancing the operational life and compatibility of battery cells with various assembly configurations.

Implementation Method 1

a resistance of the current collector may be advantageously controlled while abiding by these limitations

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

prevents localized heating

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20260045652A1Current collector for a battery cell

Publication Date: 2026.02.12 NORTHVOLT AB

AI summary

There is disclosed herein a current collector (300) for a battery cell, comprising a first section (302) comprising a first end (301) configured to connect to an electrode assembly of the cell, and a second section (304) angled relative to the first section (302) comprising a second end (303) configured to connect to a terminal of the cell. A current path is formed from the first end (301) to the second end (303), and a cross-sectional area of the current collector (300) decreases along the current path from the first end (301) to the second end (303) or from the second end (303) to the first end (301).