Jelly-roll Battery Notches for Tab Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional jelly-roll battery designs suffer from reduced energy density due to the additional space required for connections between anode and cathode layers and conductive tabs, which increases the overall profile of the battery cell.
Innovation Solution
Incorporating common notches along the sides of the jelly-roll battery cell to accommodate conductive tabs, allowing for more efficient bonding and connection of electrode tabs within these notches, thereby reducing the space needed for external connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional jelly-roll battery designs are used with external conductive tabs, then power can be provided to external circuitry, but the overall profile of the battery cell increases and energy density decreases
Solution Approach 1:
The conductive tabs are nested within notches formed in the jelly-roll structure itself. The notches create recesses that accommodate the tabs, allowing them to be integrated into the battery cell profile rather than protruding externally. This nesting approach reduces the overall volume occupied by connection components while maintaining electrical connectivity to external circuitry.
Solution Approach 2:
The active material is selectively removed from regions where conductive tabs will be positioned, creating notches in the jelly-roll structure. This extraction of material in specific locations allows the tabs to be bonded within the notches, reducing the space required for connections and thereby improving energy density without significantly increasing the battery cell profile.
2Reliability
If connections to conductive tabs are made externally, then electrical connectivity is achieved, but wasted space increases and effective energy density decreases
Solution Approach 1:
The notches serve dual functions: they provide structural integration into the jelly-roll and simultaneously serve as bonding locations for the conductive tabs. By merging the structural feature (notch) with the electrical connection function, the design eliminates wasted space while maintaining reliable electrical connectivity. The tabs are bonded within the notches, combining mechanical support and electrical connection in a single integrated feature.
3Quantity of substance
If notches are formed in the jelly-roll to accommodate tabs, then space for connections is reduced and energy density increases, but manufacturing complexity increases
Solution Approach 1:
The notches are formed in the jelly-roll structure before the conductive tabs are bonded. This preliminary action of creating the notches in advance allows for precise positioning and integration of the tabs, simplifying the subsequent bonding process. By preparing the notches beforehand, the manufacturing process becomes more systematic and controllable, reducing overall complexity despite the additional step.
Solution Approach 2:
The formation of notches involves removing material in specific locations, changing the geometric parameters of the jelly-roll structure. This parameter change creates the necessary recesses for tab accommodation, enabling space-efficient connections. The controlled modification of the jelly-roll geometry through notch formation allows integration of connection features without significantly complicating the manufacturing process.
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
This design enhances energy density by allowing additional active material on the cathode and anode layers and reduces impedance in the battery connections, leading to a more compact and efficient battery cell.
Implementation Method 1
a common cathode tab is bonded to each uncoated cathode tab within the first common notch, and a common anode tab bonded to each uncoated anode tab within the second common notch
Implementation Method 2
the common anode tab is bonded to the uncoated anode tabs by folding the uncoated anode tabs; bonding the folded uncoated anode tabs together; and bonding the common anode tab to the folded-and-bonded uncoated anode tabs
Implementation Method 3
Active material on the cathode layer and the anode layer is ablated from regions associated with a cathode tab and the anode tab
Data Source
AI summary
The disclosed embodiments relate to the design of a jelly-roll battery comprising an alternating anode and cathode layers coated with intervening separator layers wound into a jelly-roll. The alternating anode and cathode layers are coated with, respectively, an anode active coating and a cathode active coating. A first common notch and a second common notch are formed along at least one side of the jelly-roll. A common cathode tab can be bonded to the cathode tabs within the first common notch, and a common anode tab can be bonded to the anode tabs within the second common notch. The jelly-roll battery also includes a pouch enclosing the jelly-roll. Common anode and cathode tabs can extend through the pouch to provide cathode and anode terminals for the battery cell.