Battery Cell Current Collector Layout for Non-Overlapping Tabs

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery cell designs face challenges in maximizing energy density and power capacity due to the space occupied by tabs and current collectors, particularly in large format cylindrical cells, which can impede charge conductivity and require complex manufacturing processes.

Innovation Solution

The implementation of supplementary current collectors arranged perpendicularly to the electrode roll, with tabs extending from uncoated regions and increasing in length with radial distance, allowing for efficient charge transfer without overlapping, thereby reducing space and simplifying manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If tabs are extended from the electrode roll to the current collector, then charge transfer is enabled, but space is occupied reducing energy density

Engineering Contradiction:

Improvecharge transfer efficiencyVSAvoidspace occupied by tabs

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent transitions from a planar tab arrangement to a three-dimensional folded configuration. Tabs are folded back along the radial direction and positioned at different angular positions around the current collector, utilizing the third dimension (angular position) to arrange tabs without overlapping, thereby reducing the space they occupy while maintaining electrical connectivity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The current collector is divided into multiple angular segments, with tabs positioned at different angular positions. This segmentation allows tabs to be distributed around the current collector circumference, preventing overlap and reducing the radial space required for tab accommodation.

Inventive Principle:

Principle #1Segmentation

2Reliability

If tab length is increased to reach current collector, then electrical connectivity is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveelectrical connectivityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The tabs are pre-formed with the folded configuration during electrode roll manufacturing, before assembly into the battery cell. The folding and positioning of tabs are completed in advance, simplifying the final assembly process and reducing manufacturing complexity while ensuring proper electrical connectivity.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12476258B2Battery cell with supplemental current collectors

Publication Date: 2025.11.18 RIVIAN HOLDINGS LLC

AI summary

Aspects of the subject disclosure relate to battery cells having an electrode roll, and one or more current collectors at one or more ends of the electrode roll. Tabs extending from electrodes of the electrode roll at an end of the electrode roll may be folded into contact with the current collector at that end of the electrode roll, without overlapping the tabs. This may help to reduce the amount of space occupied by the tabs at the ends of the battery cell, which can facilitate an increase in electrode size that allows for an increased energy density and/or power capacity of the battery cell.