High Aspect Ratio Battery Electrode Foil Tab Configuration
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Solution Overview
Problem
Lithium ion batteries face challenges in optimizing the design of electrode foils and coatings to enhance performance and efficiency, particularly in achieving a balance between current density and manufacturing efficiency, while minimizing waste and improving heat dissipation.
Innovation Solution
The design features a specific configuration of electrode foils with long-to-short edge ratios of at least five, featuring tabs that extend from the long edges and are oriented to reduce electron travel distance, along with a method for forming electrodes using a coating machine that applies coatings and cuts the foils to create electrodes with large tabs, reducing waste and improving heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode foils with conventional aspect ratios are used, then manufacturing is simpler, but current distribution and heat dissipation are insufficient
Solution Approach 1:
The patent applies asymmetry by configuring electrode foils with high aspect ratios (length-to-width ratio of at least 2, preferably at least 5) and positioning tabs asymmetrically on the long edges rather than centers. This asymmetric configuration optimizes current distribution pathways and improves heat dissipation efficiency while maintaining manufacturability through standardized coating and cutting processes.
2Length of moving object
If tabs are positioned at the center of long edges, then manufacturing is easier, but electron travel distance is maximized
Solution Approach 1:
The patent applies local quality by positioning tabs at specific locations along the long edges of electrode foils, entirely between one short edge and the midpoint of the long edge. This localized optimization reduces electron travel distance from the active material to the tab, improving current collection efficiency while maintaining ease of manufacture through standardized positioning relative to the foil geometry.
3Temperature
If electrode foils with high aspect ratios are used, then heat dissipation improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by specifying that the tab extends entirely between one short edge and the midpoint of the long edge, with the tab length being at least 45% of the length of the electrode foil body. These parameter definitions provide clear manufacturing targets while the high aspect ratio geometry inherently improves heat dissipation. The standardized parameters balance manufacturing precision requirements with thermal performance.
4Loss of substance
If conventional coating methods are used, then manufacturing is faster, but material waste increases
Solution Approach 1:
The patent applies segmentation by dividing the electrode foil into distinct functional zones: a body portion with active material coating and tab portions extending from the long edges. The coating method applies coating material to the moving foil in a pattern that leaves uncoated tab regions, then cutting separates the electrode into individual cells. This segmentation reduces material waste by avoiding coating of tab areas that would otherwise require trimming.
Data Source
AI summary
A battery includes a first mono cell formed from a first electrode foil having a first body and a first tab, and a first coating. The first body has long edges and short edges, and a length-to-width ratio of the first body is at least five. The first tab extends from one of the long edges of the first body entirely between one of the short edges a midpoint of the long edge. A second electrode foil has similar structure to the first electrode foil and coating, but a second tab is aligned opposite the first tab along the short edges. A second mono cell has similar structure. A third tab and a fourth tab of the second mono cell are on an opposing side of the midpoint of the long edges from the first tab and the second tab.