Battery Current Collector Fusing Layout for High-Output Cells
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Solution Overview
Problem
Conventional current collectors in battery cells face challenges in accurately positioning the fusing portion, leading to difficulties in preventing foreign substance occurrence and current reconnection during fusing, and are not suitable for high-output applications due to low allowable current and inconsistent fusing function.
Innovation Solution
A current collector design featuring a first coupling portion, second coupling portion, bridge portions, and fusing induction portions that are strategically positioned and insulated to control fusing, including a tape-like fusing induction portion that wraps around the bridge portions to enhance positioning accuracy and prevent heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fusing portion is provided in the current collector to block high current, then the battery cell safety is improved, but the positioning accuracy of the fusing portion deteriorates
Solution Approach 1:
The current collector is divided into multiple bridge portions (first, second, third bridge portions) connecting the first and second coupling portions. Each bridge portion can be independently designed with specific fusing induction portions, allowing precise control of fusing locations without affecting the entire current collector structure.
Solution Approach 2:
Fusing induction portions are selectively provided only in specific bridge portions where fusing is required, rather than uniformly across the entire current collector. This localized approach enables precise positioning control and maintains manufacturing accuracy while ensuring safety functionality.
2Manufacturing precision
If the fusing portion is positioned accurately, then the fusing function is improved, but the occurrence of foreign substances during fusing cannot be prevented
Solution Approach 1:
A tape-like insulating structure is introduced as an intermediary element that wraps around the bridge portions. This insulating structure serves as a mediator that prevents direct contact between fusing materials and surrounding components, thereby preventing foreign substance generation while maintaining accurate fusing positioning.
Solution Approach 2:
The tape-like insulating structure acts as a flexible thin film that can be wrapped around the bridge portions conformally. This flexible insulation layer prevents foreign substance occurrence during fusing by isolating the fusing zone without rigid constraints that could cause contamination.
3Power
If the fusing portion allows high current flow, then the allowable current is improved, but the fusing function becomes inconsistent
Solution Approach 1:
The current collector design allows dynamic current distribution across multiple bridge portions. Each bridge portion with fusing induction portions can independently handle high current loads, and the system adapts by distributing current flow dynamically, maintaining both high allowable current and consistent fusing function.
Solution Approach 2:
By changing the physical parameters of the bridge portions (such as cross-sectional area, material properties, and configuration of fusing induction portions), the current collector can maintain consistent fusing characteristics even when handling high current loads. The parameters are optimized to ensure uniform current distribution and predictable fusing behavior.
4Power
If the fusing portion is designed for high-output battery cells, then the power capability is improved, but the positioning and insulation control becomes more difficult
Solution Approach 1:
The current collector is segmented into multiple standardized bridge portions, each with defined dimensions and fusing induction portions. This segmentation allows for modular manufacturing with precise positioning, while the overall structure can be scaled to meet high-power requirements by adjusting the number and configuration of bridge portions.
Solution Approach 2:
Insulation and fusing induction portions are applied locally to specific bridge portions rather than uniformly across the entire current collector. This localized approach simplifies manufacturing and positioning control for high-power applications, as only critical areas require precise insulation and fusing features.
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
The design allows for precise fusing control, prevents foreign substance occurrence, and maintains high output capability while ensuring the fusing function is effective, with improved productivity through strategic placement and insulation of the fusing induction portions.
Implementation Method 1
a plurality of fusing induction portions provided in the respective bridge portions and configured to cover at least a portion of the bridge portion
Implementation Method 2
when a high current exceeding the allowable current flows, the temperature of the battery cell may rise irregularly
Data Source
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AI summary
A current collector according to the present disclosure may include: a first coupling portion coupled with a first terminal; a second coupling portion coupled with an electrode assembly; a plurality of bridge portions configured to connect the first coupling portion and the second coupling portion; and a plurality of fusing induction portions provided in the respective bridge portions and configured to cover at least a portion of the bridge portion.