Electrochemical Cell Collector Coating for Safer Welding
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Solution Overview
Problem
Existing electrochemical cells face challenges with high internal resistance and the risk of short circuits due to the mechanical sensitivity of thin current collectors during welding, especially when handling high currents, and the difficulty in manufacturing cells with improved current-carrying capacity and manufacturability.
Innovation Solution
The electrochemical cell design incorporates anode and cathode current collectors with thermally more resistant ceramic or glass-based support materials in free areas not loaded with electrode active materials, which enhances mechanical stability and prevents melting during welding, reducing the risk of short circuits and improving manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal foils are used to electrically connect current collectors to the housing, then the electrical connection is simple and cost-effective, but the metal foils heat up considerably when high currents are stored or delivered
Solution Approach 1:
The invention extracts the problematic metal foil intermediate connector from the electrical connection path. Instead of using metal foils to connect current collectors to the housing, the current collectors are directly welded to the housing, eliminating the source of excessive heating while maintaining manufacturing simplicity
Solution Approach 2:
The invention uses composite material structure where the housing serves dual functions as both mechanical enclosure and electrical conductor. By integrating the electrical connection function into the housing structure itself, the design eliminates the need for separate metal foil connectors and reduces thermal issues
2Reliability
If contact plates are welded to the longitudinal edges of current collectors, then the internal resistance is significantly reduced and current carrying capacity is improved, but the thin current collectors are mechanically sensitive and can be unintentionally depressed or melted during welding
Solution Approach 1:
The invention applies preliminary protective action by coating the current collector surface with a ceramic layer before welding. This protective coating prevents the thin current collector from melting or deforming during the welding process, enabling successful welding operations without compromising manufacturing precision
Solution Approach 2:
The ceramic coating acts as an intermediary protective layer between the welding heat source and the thin current collector. This intermediate layer absorbs and distributes the thermal energy, preventing direct contact between the welding arc and the sensitive current collector material
3Reliability
If contact plates are welded to the current collectors, then electrical contact is achieved along the entire length, but the separators can melt when the contact plates are welded on, resulting in short circuits
Solution Approach 1:
The ceramic coating on the current collector serves as a thermal intermediary that protects surrounding components during welding. By absorbing and distributing welding heat, the coating prevents thermal damage to separators and other sensitive components, eliminating the risk of melting and short circuits
Solution Approach 2:
The invention applies preliminary protective measures by pre-coating the current collector with heat-resistant ceramic material before welding operations. This preliminary protection creates a thermal barrier that prevents harmful heat transfer to separators and other components during the welding 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
The use of thermally stable support materials on the current collectors improves the cell's ability to handle high currents by reducing internal resistance and mechanical sensitivity, enhancing manufacturability and safety by preventing short circuits and melting issues.
Implementation Method 1
the surface of the anode current collector and/or the surface of the cathode current collector comprises at least one free area that is not loaded with the respective electrode active material, wherein in the at least one free area the surface of the anode current collector and/or the surface of the cathode current collector is coated with a support material that is more thermally resistant than the surface to which it is coated
Implementation Method 2
an electrochemical cell with an electrode-separator assembly comprising an anode, at least one separator and a cathode
Data Source
Figure 1~6
Figure 7~8
AI summary
An electrochemical cell (100) comprises an electrode-separator assembly (101) with an anode (115), at least one separator (116, 117), and a cathode (118). The anode (115) and the cathode (118) each comprise a current collector (115a, 118a) having a surface made of at least one metal, which is loaded with at least one layer (115b, 118b) of an electrode active material. The surfaces of the current collectors (115a, 118a) comprise at least one free region (115c, 118c) that is not loaded with the electrode active material. Instead, in the at least one free region (115c, 118c), they are coated with a support material (119) that is more thermally resistant than the surface to which it is coated. During the manufacture of the cell (100), the support material (119) can be applied to or formed on the at least one free area (115c, 118c) before or after the manufacture of the electrode-separator assembly (101).