Cylindrical Battery Cell Extensions for Radial Tab Alignment
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Solution Overview
Problem
Existing cylindrical battery cell designs, such as single tab, multiple tab, and tabless configurations, face challenges in efficiently aligning and connecting uncoated extensions, which affects the battery's performance and manufacturing complexity.
Innovation Solution
The electrode for a cylindrical battery cell features multiple uncoated extensions that align with each other when rolled, allowing them to be connected to a tab. These extensions increase in size and spacing along the electrode, ensuring alignment and tolerance for rolling variations, and can be folded over to contact each other and the tab.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple tabs are used in traditional cylindrical battery cells, then electrical connection is improved, but alignment precision and manufacturing complexity worsen
Solution Approach 1:
The electrode is divided into multiple uncoated extensions along the rolled direction, each serving as a separate connection point. These extensions are spaced at specific intervals to ensure they align radially when rolled, creating multiple electrical connection paths without requiring complex multi-tab assemblies. The segmentation allows each extension to be independently positioned for optimal alignment.
Solution Approach 2:
The solution transitions from a planar tab arrangement to a three-dimensional radial alignment when rolled. By spacing extensions along the rolled direction and making them increase in width, the design exploits the radial dimension created by rolling to achieve precise alignment. The extensions fold radially inward to contact the collector, utilizing the cylindrical geometry to simplify what would otherwise be a complex two-dimensional alignment problem.
2Ease of manufacture
If traditional tab designs are used, then manufacturing process is simpler, but electrical pathway efficiency worsens
Solution Approach 1:
The uncoated extensions are pre-formed on the electrode during manufacturing with specific spacing and width variations. This preliminary configuration ensures that when the electrode is rolled, the extensions automatically align radially and fold into contact with the collector without requiring additional alignment steps or complex assembly operations. The electrical pathways are pre-established through the extension design.
Solution Approach 2:
Different regions of the electrode have different properties: the uncoated extensions have varying widths that increase along the rolled direction, while the coated regions maintain consistent thickness. This local variation in extension width ensures optimal alignment and contact area at each radial position, improving electrical pathway efficiency without compromising overall manufacturability.
3Ease of manufacture
If uncoated extensions are spaced evenly, then manufacturing is easier, but alignment precision when rolled worsens
Solution Approach 1:
The extensions are spaced asymmetrically along the rolled direction rather than evenly. The spacing between adjacent extensions increases progressively, and the width of each extension varies according to its position. This asymmetric design compensates for the radial geometry created by rolling, ensuring that extensions at different radii align precisely with the collector while maintaining a manufacturable process.
Data Source
AI summary
Aspects of the disclosure relate to a battery cell that includes a rolled electrode layer having a coated region, and multiple uncoated extensions that are radially aligned with each other, such as along a direction extending radially from a center of the rolled electrode layer.