Battery Current Collector Edge Shaping for Reliable Contact
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Solution Overview
Problem
Existing lithium-ion energy storage elements face challenges in achieving reliable and efficient electrical contact due to uncontrolled compression of current collector edges during contact plate application, leading to undefined folds and increased risk of short circuits.
Innovation Solution
The energy storage element design features cathode and anode current collectors with U-shaped or V-shaped free edge strips, which are formed to create elongated depressions and elevations, allowing for defined folding and improved contact with contact sheet metal members, reducing internal resistance and the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact plates are applied to current collectors during assembly, then electrical contact is established, but uncontrolled compression occurs causing undefined folds and increasing short circuit risk
Solution Approach 1:
The edge strip is pre-formed with a U-shaped or V-shaped cross-section before assembly, creating predetermined elevations and depressions. This preliminary shaping allows the edge strip to fold in a controlled manner during contact plate application, preventing uncontrolled compression and undefined folds while maintaining reliable electrical contact.
Solution Approach 2:
The cross-sectional geometry of the edge strip is changed from a flat configuration to a U-shaped or V-shaped configuration with specific elevations and depressions. This parameter change in shape allows the material to deform in a predictable way during compression, transforming the uncontrolled folding problem into a controlled folding solution that maintains contact reliability.
2Reliability
If current collectors are compressed during contact plate application, then electrical contact is achieved, but internal resistance increases due to uncontrolled deformation
Solution Approach 1:
The edge strip is pre-formed with a U-shaped or V-shaped cross-section before assembly, creating predetermined elevations and depressions. This preliminary shaping allows the edge strip to fold in a controlled manner during contact plate application, preventing uncontrolled compression and undefined folds while maintaining reliable electrical contact.
Solution Approach 2:
The cross-sectional geometry of the edge strip is changed from a flat configuration to a U-shaped or V-shaped configuration with specific elevations and depressions. This parameter change in shape allows the material to deform in a predictable way during compression, transforming the uncontrolled folding problem into a controlled folding solution that maintains contact reliability.
Data Source
AI summary
The following is known: energy-storage elements (100) comprising a cathode (101) and an anode (102), which cathode and anode are parts of a composite body (109) in that they are provided, separated by a separator layer or solid-electrolyte layer (110), in the following sequence: cathode (101)-separator layer or solid-electrolyte layer (110)-anode (102), wherein the cathode (101) and the anode (102) comprise current collectors (101a and 102a) which each have, in addition to regions (101b and 102b) coated on both sides with electrode material (117 and 118), one edge strip (101c and 102c) which is not coated with electrode material. Here, the free edge strip (101c) of the cathode current collector (101a) exits on one side of the composite body (109), and the free edge strip (102c) of the anode current collector (102a) exits on another side of the composite body (109), wherein one of the edge strips (101c, 102c) is in direct contact with a first contact sheet (119), and the other one is in direct contact with a second contact sheet (120). According to the present invention, at least one of the edge strips (101c, 102c) which is in direct contact with one of the contact sheets (119, 120) is subjected to a shaping process, so that this edge strip has a U-shaped or V-shaped cross-section and therefore an elongate recess or depression (121, 124) on one side and an elongate raised portion (122, 123) corresponding to the recess on the other side.