Battery Current Collector Crimp Structure for Low-Resistance Coupling
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Solution Overview
Problem
Existing batteries face challenges in reducing self-resistance of the jelly-roll structure, improving coupling force between the current collector and battery housing, and enhancing energy density while ensuring high output and capacity, particularly for applications in electric vehicles.
Innovation Solution
A battery design featuring a current collector with a tab coupling portion and housing coupling portion, including a beading and crimping structure, which reduces resistance and improves coupling force, energy density, and manufacturing convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of tabs for connecting the jelly-roll to the external terminal is increased, then the resistance is reduced, but the device complexity increases
Solution Approach 1:
The current collector is divided into multiple segments (first current collector and second current collector) that are positioned at different locations within the battery housing. Each segment connects to the jelly-roll at different points, creating multiple parallel current paths without requiring excessive tabs on a single collector. This segmentation reduces overall resistance while maintaining manageable device complexity.
Solution Approach 2:
Instead of increasing tabs in the planar dimension, the patent introduces a spatial dimension by positioning current collectors at different heights and locations within the battery housing (first end and second end). This three-dimensional arrangement creates multiple current paths through space rather than through additional tabs, reducing resistance without proportionally increasing complexity.
2Quantity of substance
If the form factor of the battery is increased, then the energy density is increased, but the coupling force between current collector and battery housing may be reduced
Solution Approach 1:
The current collection function is segmented across multiple collectors positioned at different locations and orientations within the battery. This segmentation allows each current collector to be optimized for its specific position, ensuring adequate coupling force with the battery housing at each location while accommodating the larger form factor required for high energy density.
Solution Approach 2:
Different current collectors are positioned at different locations (first end and second end of the battery housing) with potentially different configurations. This allows local optimization of the coupling structure at each end to match the specific mechanical and electrical requirements of that region, maintaining strong coupling force throughout the larger battery form factor.
3Reliability
If a new jelly-roll structure is developed to reduce self-resistance, then the resistance is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The welding structure is segmented into multiple current collectors positioned at different locations within the battery housing. Each collector welds to the jelly-roll at different points, distributing the manufacturing complexity across multiple simpler welding operations rather than requiring one complex multi-tab connection. This reduces the precision required for each individual welding operation while achieving low overall resistance.
Data Source
AI summary
A battery includes an electrode assembly including a first electrode, a second electrode, and a separator between the first electrode and second electrode, a first portion including an active material extending between a pair of first sides, and a second portion extending between the pair of first sides and exposed beyond the separator, at least a part of the second portion includes an electrode tab; a battery housing having a first end with a first opening, a second end opposite the first end, and an inner surface, the battery housing accommodating the electrode assembly; a first current collector including a tab coupling portion coupled to the second portion of the first electrode and a housing coupling portion extending from the tab coupling portion and electrically coupled to the inner surface of the battery housing; and a cap covering the first opening of the battery housing.