Energy Storage Element Terminal Structure Without Separate Conductor
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Solution Overview
Problem
Existing lithium-ion energy storage elements, such as those described in WO 2017/215900 A1, require a separate electrical conductor for connecting the contact plate to the housing, which occupies space and increases assembly complexity, limiting the energy density and internal resistance.
Innovation Solution
The energy storage element features a metal part that serves as both a housing closure and a current diverter, eliminating the need for a separate electrical conductor by using a free edge strip from the current collector to establish electrical contact, thereby reducing internal resistance and increasing usable volume for active material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate electrical conductor is used to connect the contact plate to the housing, then reliable electrical connection is achieved, but device complexity and assembly steps increase
Solution Approach 1:
The patent merges the housing closure function and electrical connection function into a single integrated metal part. The metal part simultaneously serves as the housing closure element and as the electrical conductor connecting the current collector to the external circuit, eliminating the need for separate electrical conductors and reducing assembly complexity while maintaining reliable electrical connection
Solution Approach 2:
The metal part is designed to perform multiple functions: it acts as both the housing closure element and the electrical conductor. This multi-functional design reduces the total number of components required and simplifies the assembly process while ensuring reliable electrical connection between the current collector and external circuits
2Reliability
If a separate electrical conductor is used for connecting contact plate to housing, then electrical connection is established, but usable volume for active material decreases
Solution Approach 1:
By combining the housing closure and electrical connection functions into one metal part, the patent eliminates the space required for separate electrical conductors. This integration maximizes the usable volume within the housing for accommodating active material, while still establishing reliable electrical connection
3Quantity of substance
If more active material is incorporated to increase energy density, then energy storage capacity increases, but internal resistance and assembly complexity increase with traditional designs
Solution Approach 1:
The integrated metal part design reduces assembly complexity, making it more suitable for high-volume production of energy storage devices with increased active material content. The simplified structure facilitates easier assembly while accommodating larger quantities of active material for higher energy density
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 more active material to be incorporated and simplifies manufacturing, reducing internal resistance and assembly complexity.
Implementation Method 1
a metal part, which covers the first terminal end face, i.e. the metal part comprises a flat area to which the free edge strip protruding from the first terminal end face is welded, and a projection pointing away from the first terminal end face
Implementation Method 2
the free edge strip protruding from the first terminal end face is welded
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5F
AI summary
The invention relates to an energy storage element comprising an electrode-separator assembly in a housing. It further comprises a metal part that covers a first terminal end face of the electrode-separator assembly and is welded to a free edge strip of a current collector projecting from this end face. The metal part further comprises a projection extending away from the end face, the projection being inserted into or extending through an opening in the base of the housing, so that the projection can be mechanically contacted from outside the housing. The invention further relates to a method for manufacturing such an energy storage element.