Composite Current Collector Protection Layer for Battery Cell Headspace

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The connection of a composite current collector to an electrode terminal through welding results in a weld mark, leading to issues such as battery capacity loss, deformation, and increased risk of electrode terminal breakage due to the need to avoid the weld mark, which occupies headspace and complicates the folding process.

Innovation Solution

A battery cell design incorporating a protection layer on the composite current collector to isolate burrs, with specific width and thickness parameters, along with a conductive undercoat to enhance bonding and electron transport, thereby increasing headspace and facilitating electrode terminal bending.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the electrode terminal avoids the weld mark position, then the reliability of connection is improved, but the headspace of the battery cell is reduced and the electrode terminal is prone to breakage

Engineering Contradiction:

Improveconnection reliabilityVSAvoidheadspace

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent introduces a protection layer as an intermediary component between the composite current collector and the electrode terminal. This protection layer covers the weld mark area, allowing the electrode terminal to be positioned over the weld mark without compromising connection reliability, thereby preserving headspace and preventing terminal breakage

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the protection layer width is reduced, then the headspace is increased, but the burr isolation capability may be compromised

Engineering Contradiction:

ImproveheadspaceVSAvoidburr isolation

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent optimizes the width parameter of the protection layer to a specific range that simultaneously achieves adequate burr isolation and maximizes headspace. By precisely controlling this dimensional parameter, the design resolves the contradiction between safety functionality and space utilization

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20260031414A1Battery cell and electrical device

Publication Date: 2026.01.29 NINGDE AMPEREX TECHNOLOGY LTD

AI summary

A composite current collector includes a first section, a second section, and a third section arranged along a first direction. The second section connects the first section and the third section. The first active material layer is connected to the first section. The first active material layer and the composite current collector are arranged along a second direction. The first direction is perpendicular to the second direction. The protection layer is connected to the second section. A first electrical connector is connected to the third section. The protection layer, the first active material layer, and the first electrical connector are disposed on a same side of the composite current collector. Along the first direction, a width W1 of the protection layer satisfies: 1.0 mm≤W1≤2.4 mm. The second direction is a thickness direction of the first electrode plate.