Electrochemical Cell Current Collector Encapsulation
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Solution Overview
Problem
Conventional electrochemical cells, particularly film batteries, face issues with mechanical flexibility and energy density due to the deterioration of metal foil current collectors under repeated bending and the space-consuming interconnection of connector tabs, which limits their performance and durability.
Innovation Solution
The electrochemical cell design replaces the conventional housing with anode and cathode current collectors that form an encapsulating housing, providing mechanical stability and integrating connector tabs, while using amorphous metallic or fiber-reinforced plastic materials for enhanced flexibility and conductivity, and a seal to prevent electrolyte leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metal foil current collectors are used, then electrical conductivity is provided, but mechanical flexibility deteriorates after repeated bending operations
Solution Approach 1:
The current collector material is changed from conventional metal foil to a polymer-based material with specific mechanical properties. The polymer material exhibits elastic deformation capability and resistance to fissuring even after repeated bending operations, fundamentally changing the material parameter to resolve the contradiction between flexibility and durability.
Solution Approach 2:
The current collector is constructed as a composite structure comprising a polymer base material with embedded conductive elements. This composite approach maintains electrical conductivity while the polymer matrix provides the necessary mechanical flexibility and resistance to bending-induced damage.
2Ease of manufacture
If connector tabs are interconnected with current collectors inside housing, then electrical connection is established, but spatial energy density is reduced
Solution Approach 1:
The connector tabs are integrally formed with the current collector as a single piece, eliminating the need for separate interconnection components and their associated housing structures. This merging of functions reduces the space required for connections and increases the volumetric energy density of the battery.
Solution Approach 2:
The connector tabs are extracted from the internal housing structure and extended through the housing wall to the exterior. This eliminates the need for internal interconnection space and allows the tabs to be directly accessible for electrical connection, thereby increasing the active volume for energy storage.
3Ease of operation
If current collectors are arranged at outside facing portions, then electrical connection is facilitated, but mechanical stress increases during bending
Solution Approach 1:
The current collector material is changed to a polymer-based composite that inherently possesses higher resistance to mechanical stress during bending. This material parameter change allows the current collector to maintain structural integrity and electrical functionality even when arranged at the outside facing portions subject to maximum bending stress.
Data Source
AI summary
The present invention relates to an electrochemical cell, comprising:an anode in contact with an anode current collector,a cathode in contact with a cathode current collector,a separator disposed between the anode and the cathode, wherein the anode is disposed between the separator and the anode current collector and wherein the cathode is disposed between the separator and the cathode current collector,wherein the anode current collector and the cathode current collector form an encapsulating housing for the assembly of anode, cathode and separator.