Battery Current Collector Structure for Low-Resistance Tab Coupling
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Solution Overview
Problem
Conventional cylindrical batteries face challenges with high resistance, limited current path, and susceptibility to damage from vibrations and impacts, particularly in high-output applications like electric vehicles, necessitating improvements in current collector structure and coupling strength.
Innovation Solution
A current collector design with a support portion, tab coupling portions, and housing coupling portions that are indirectly connected, featuring asymmetrical beading portions and welding patterns to reduce resistance and enhance coupling strength, while minimizing damage from impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of tabs is increased to reduce resistance, then the current path is improved, 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 coupled to different portions of the electrode assembly. This segmentation allows current to flow through multiple parallel paths, effectively reducing resistance without requiring an excessive number of tabs on a single collector.
Solution Approach 2:
The patent transitions from a single-plane tab arrangement to a multi-dimensional current collection system where collectors are positioned at different locations and orientations on the electrode assembly, creating multiple current paths in different spatial dimensions.
2Ease of manufacture
If the current collector structure is simplified for easier manufacture, then the manufacturing precision may be compromised
Solution Approach 1:
The patent specifies precise geometric parameters for the current collectors including width (10-50mm), length (20-100mm), and thickness (0.5-2mm), as well as positioning distances from the electrode assembly center (15-40mm). These controlled parameter variations enable standardized welding procedures while maintaining consistent coupling strength and electrical performance.
3Quantity of substance
If the battery housing space is minimized for higher energy density, then the coupling strength between current collector and housing may be reduced
Solution Approach 1:
The current collectors are pre-positioned and coupled to the electrode assembly before final housing assembly. This preliminary coupling ensures proper alignment and establishes strong electrical connections early in the manufacturing process, allowing the housing to be tightly fitted without compromising connection strength.
Solution Approach 2:
The patent applies different coupling strategies at different locations: the first current collector couples to the housing at one end while the second current collector couples at the opposite end. This localized quality approach distributes mechanical and electrical stresses throughout the structure, maintaining both energy density and coupling strength.
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 design significantly reduces resistance, improves energy density, enhances coupling strength, and increases manufacturing productivity by facilitating easier welding processes, while minimizing damage from vibrations and impacts.
Implementation Method 1
A current collector having a support portion to be positioned on an electrode assembly of the battery, a plurality of tab coupling portions extending from the support portion and to be coupled with a portion of an electrode of the electrode assembly, and a first housing coupling portion extending from the support portion and to be electrically coupled onto a inner surface of the battery housing
Implementation Method 2
a first housing coupling portion extending from the support portion and to be electrically coupled onto a inner surface of the battery housing
Data Source
AI summary
A current collector of a battery having a support portion to be positioned on an electrode assembly of the battery, tab coupling portions extending from a perimeter of the support portion and to be coupled with a portion of an electrode of the electrode assembly, each tab coupling portion ending in a free end spaced from the support portion, and a first housing coupling portion extending from the perimeter of the support portion, disposed between adjacent tab coupling portions and to be electrically coupled onto a beading portion of a battery housing of the battery, the first housing coupling portion being separate from the adjacent tab coupling portions so as to not contact the adjacent tab coupling portions. A battery is also provided.