Co-wound Battery Guidewire Low Impedance Endcap Design
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Solution Overview
Problem
Traditional battery designs face issues with high electrical impedance, poor thermal response, and inadequate integration of cell ends with terminals, leading to power loss and heat dissipation problems, especially in high-power applications.
Innovation Solution
A coiled battery assembly is created by coaxially winding negative and positive electrode sheets with a separator in between, where edges without electrode active material are used with conductive guidewires to form endcaps for connection with terminals, reducing impedance and enhancing thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional battery designs use collector sheets and rolled configurations, then mechanical stability and compactness are achieved, but electrical impedance increases and power loss occurs
Solution Approach 1:
The patent extracts the problematic collector sheets from the battery structure and replaces them with a simple conductive wire running through the center of the rolled assembly. This removal of unnecessary components reduces electrical impedance and simplifies the overall structure while maintaining mechanical stability through the rolled configuration itself.
Solution Approach 2:
The invention applies local quality by using a conductive wire specifically at the critical connection points (ends of the rolled assembly) rather than throughout the entire structure. This localized approach provides necessary electrical connectivity where needed while avoiding the impedance issues associated with traditional collector sheets covering the entire battery surface.
2Temperature
If traditional battery designs use rigid cylindrical enclosures, then mechanical protection is provided, but thermal response and heat dissipation capabilities are poor
Solution Approach 1:
The patent segments the battery structure by unwrapping or partially opening the rigid cylindrical enclosure to create an expanded configuration. This segmentation allows heat to dissipate from multiple surfaces rather than being trapped within a sealed cylinder, improving thermal response while maintaining mechanical protection through the enclosing structure.
Solution Approach 2:
The invention transitions from a purely two-dimensional rolled assembly to a three-dimensional expanded structure where the battery layers are separated and positioned to maximize surface area for heat dissipation. This dimensional change allows heat to escape in multiple directions rather than being confined to the cylindrical geometry.
3Ease of operation
If traditional battery designs use rolled jelly roll configurations, then compactness and mechanical stability are achieved, but the ends are not well integrated with terminals
Solution Approach 1:
The conductive wire serves multiple functions: it provides electrical connectivity between the rolled assembly and terminals, acts as a structural anchor holding the rolled layers together, and facilitates heat transfer from the battery interior to the terminals. This multi-functionality improves terminal integration without requiring additional components that would increase volume.
Solution Approach 2:
The conductive wire acts as an intermediary element that bridges the rolled battery assembly and the external terminals. Rather than directly connecting the bulky rolled structure to terminals, the wire provides a streamlined interface that improves integration while maintaining compactness.
4Reliability
If traditional battery designs use multiple collector sheets, then electrical connectivity is provided, but impedance increases and connection between collectors is problematic
Solution Approach 1:
The patent removes the multiple collector sheets that cause impedance issues and replaces them with a single continuous conductive wire. This extraction eliminates the problematic interfaces between multiple collector sheets while maintaining reliable electrical connectivity through the simplified wire structure.
Solution Approach 2:
The invention uses a composite structure where the conductive wire is integrated with the rolled battery assembly, creating a unified electrical pathway. This composite approach combines the simplicity of a wire with the structured arrangement of the rolled layers to achieve low-impedance connectivity without the complexity of multiple separate collector sheets.
Data Source
AI summary
An electro-chemical storage device is described, and a method for making the same. In some aspects, a guidewire is co-wound with sheet or ribbon-like electrode materials so that contact is made between the guidewire and collector extensions of the electrode materials thereby forming an endcap with low impedance and high thermal sinking capabilities. In one embodiment, the storage device includes a negative electrode sheet have an edge which is substantially free of electrode active material, a positive electrode sheet have an edge which is substantially free of electrode active material, a first conductive guidewire disposed adjacent to the edge of the negative electrode sheet which is substantially free of electrode active material, and a second conductive guidewire disposed adjacent to the edge of the positive electrode sheet which is substantially free of electrode active material. The first conductive guidewire and the edge of the negative electrode sheet which is substantially free of electrode active material define a first electrode endcap and the second conductive guidewire and the edge of the positive electrode sheet which is substantially free of electrode active material define a second electrode endcap. The electrode endcaps are coupled to terminals of the storage device, which are capable of being connected to the terminals of an external circuit.