Cylindrical Cell Cover Assembly to Eliminate Dead Volume
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lithium-ion energy storage elements, particularly cylindrical round cells, face challenges in achieving high energy density while maintaining the ability to handle high currents and ensuring safety, with dead volumes in their construction negatively impacting energy density and safety features.
Innovation Solution
The design incorporates an airtight and liquid-tight housing with a metallic cup-shaped housing part and a cover component that includes a connection pole electrically insulated from the cover plate, allowing for compact construction and efficient electrical contact of both anode and cathode via the cover component, with integrated safety features like a metallic membrane and grooves for pressure equalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional cylindrical round cell construction is used, then the cell can provide high currents, but dead volumes reduce energy density
Solution Approach 1:
The patent merges the cover component with the connection pole structure, eliminating the need for separate connection components and reducing dead volumes. The cover plate is integrated with the connection pole to form a unified structure that contacts both electrodes, thereby maximizing space utilization and improving energy density while maintaining high current capability.
2Reliability
If safety features like pressure equalization are integrated, then safety is improved, but device complexity increases
Solution Approach 1:
The pressure equalization feature is integrated into the housing base structure through grooves and a metallic membrane, combining safety functionality with the existing structural components. This approach improves safety by enabling pressure relief while avoiding the addition of separate safety mechanisms that would increase device complexity.
3Reliability
If connection pole is electrically insulated from cover plate, then electrical contact efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses a casting compound as an intermediary material that provides electrical insulation between the cover plate and connection pole while maintaining mechanical integration. This casting compound fills the space between these components, ensuring proper electrical isolation without requiring complex insulating structures, thereby achieving efficient electrical contact while keeping manufacturing relatively simple.
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 eliminating dead volumes and improves safety through efficient electrical contact and integrated pressure equalization, enabling the cells to handle high currents and pressures effectively.
Implementation Method 1
The housing base has integrated safety features for pressure equalization in the event of overpressure
Implementation Method 2
The housing base has integrated safety features for pressure equalization in the event of overpressure, including a metallic membrane and grooves
Implementation Method 3
a connection pole (102b), which is guided through an opening (102d) in the cover plate (102a) and is electrically insulated from the cover plate (102a), the contact plate (111) being electrically connected to the connection pole (102b)
Implementation Method 4
Electrochemical energy storage elements are able to convert stored chemical energy into electrical energy through a redox reaction
Implementation Method 5
The separator thus prevents direct contact between the electrodes. At the same time, however, it enables electrical charge equalization between the electrodes
Implementation Method 6
This ion current passes through the separator and is made possible by an ion-conducting electrolyte
Data Source
Figure 1A~1D
Figure 2A~2C
Figure 3A~3B
AI summary
An energy storage element (100) comprises an airtight and liquid-tight housing and an electrode-separator assembly (104) arranged therein, which includes an anode current collector (106) loaded with a layer of negative electrode material (107) and a cathode current collector (109) loaded with a layer of positive electrode material (110). The housing comprises a metallic, cup-shaped housing part (101) having a housing base (101a), a circumferential side wall and an end opening, as well as a lid component (102) that closes the end opening of the cup-shaped housing part (101). An edge (106a, 109a) of the anode current collector (106) or of the cathode current collector (109) is electrically connected to the housing base (101a) and another edge (106a, 109a) to a contact plate (111) that sits directly on this edge.The cover component (102) comprises a metallic cover plate (102a) and a terminal (102b) which passes through an opening in the cover plate (102a) and is electrically insulated from the cover plate (102). The terminal (102b) sits directly on the contact plate (111) and is welded to it. Furthermore, the terminal (102b) is electrically insulated from the cover plate (102) by a hardened potting compound (113) made of an electrically insulating plastic material. The cover component (102) can be manufactured during housing assembly.