Battery Current-Collector Connector Segmentation
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Solution Overview
Problem
The conventional current-collection structure in non-aqueous electrolyte secondary batteries faces difficulties in connecting current-collector connectors to power generating elements, particularly in large capacity batteries, leading to issues with defective welding and reduced reliability.
Innovation Solution
A battery design featuring current-collector connectors with a plate-like main portion and twisted connecting plate portions, allowing for easy connection and secure attachment to the electrodes, utilizing a simple structure made by punching, folding, and twisting metal plates, which enhances electrical conductivity and reduces the risk of stress concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the plate thickness of the current-collector connector is increased to handle large currents in large capacity batteries, then the current-carrying capacity is improved, but the welding quality deteriorates due to difficulty in welding thick plates to thin foils
Solution Approach 1:
The current-collector connector is divided into a main body portion and multiple arm portions that extend in different directions. This segmentation allows the connector to handle large currents through its substantial plate thickness while the extended arms provide optimal positioning and surface area for welding connections to thin foil electrodes, thereby resolving the contradiction between current-carrying capacity and welding quality
Solution Approach 2:
The connector extends from a two-dimensional plate into three-dimensional space through multiple arm portions that protrude in different directions. This dimensional extension allows the thick main body to carry large currents while the distributed arms provide multiple welding surfaces that are optimally positioned for reliable connection to thin foil electrodes
2Reliability
If the current-collector connector structure is made complex to improve connection reliability, then the welding quality is improved, but the manufacturing complexity increases
Solution Approach 1:
The connector is segmented into a main body and multiple arms that can be formed from a single plate through punching and bending operations. This segmentation provides reliable multi-point connections to electrodes while maintaining manufacturing simplicity through single-piece construction, avoiding the need for complex assembly of multiple separate components
Solution Approach 2:
The connector achieves reliable connections by varying geometric parameters such as arm length, arm spacing, and arm orientation rather than by increasing material complexity. These parameter changes allow optimization of welding surfaces for different electrode configurations while maintaining a simple plate-based structure that is easy to manufacture
3Productivity
If multiple current-collector connectors are used to improve current collection efficiency, then the current collection performance is improved, but the battery weight increases
Solution Approach 1:
A single current-collector connector is segmented into multiple arms that extend in different directions, effectively functioning as multiple connectors. This provides comprehensive current collection from multiple electrode surfaces while using only one connector component, thereby improving current collection efficiency without the weight penalty of multiple separate connectors
Data Source
AI summary
The metal foil of the positive electrode 1a or the negative electrode 1b in the power generating element 1 is connected along the connecting plate portion 2b which is folded, twisted, and provided in a protruding condition from the main portion 2a of the current-collector connector 2; hence the shape of the current-collector connector 2 becomes easy to form, and a battery capable of enhancing current collection efficiency, reliability and workability can be provided.