Cylindrical Battery Current Collector Layout for Low Resistance Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional cylindrical batteries face challenges with high resistance, limited current path, and susceptibility to damage from vibrations and impacts, necessitating improvements in current collector structure and coupling strength for enhanced energy density and manufacturing efficiency.
Innovation Solution
A current collector design with a support portion, tab coupling portions, and housing coupling portions that are indirectly connected via a support portion, featuring asymmetrical beading portions and welding patterns to reduce resistance and enhance coupling strength, while minimizing damage from impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the number of tabs is increased to reduce resistance, then the current path is improved, but the device complexity increases
Solution Approach 1:
The current collector is divided into multiple segments (first current collector and second current collector) that are positioned at different locations within the battery housing. Each segment provides independent electrical connection paths to the electrode assembly, effectively segmenting the current collection function to reduce resistance without requiring an excessive number of tabs on a single collector.
Solution Approach 2:
The patent transitions from a single-plane tab arrangement to a three-dimensional configuration where current collectors are positioned at different spatial locations (first end and second end of the battery housing). This dimensional change creates multiple current paths through space rather than through additional tabs on a single plane, reducing resistance while maintaining structural simplicity.
2Reliability
If the coupling strength between current collector and battery housing is improved, then the reliability is enhanced, but the manufacturing complexity increases
Solution Approach 1:
The current collectors are designed with pre-formed coupling structures (protrusions, recesses, or attachment features) that enable straightforward assembly with the battery housing. The coupling mechanism is prepared in advance during current collector manufacturing, allowing for reliable connection without complex assembly operations or additional fastening steps.
Solution Approach 2:
The patent introduces a coupling structure that acts as an intermediary between the current collector and the battery housing. This intermediary mechanism (such as protrusions fitting into recesses or dedicated mounting features) provides a simple yet reliable connection method, avoiding direct complex welding or mechanical fastening while ensuring strong coupling.
3Quantity of substance
If the current collector structure is optimized for high output/high capacity, then the energy density is improved, but the susceptibility to vibration and impact damage increases
Solution Approach 1:
The current collector design incorporates vibration-dampening features and flexible coupling mechanisms that are built into the structure before assembly. The coupling structures include elements that can absorb or dissipate vibration energy, and the multi-segment configuration provides inherent flexibility to accommodate thermal expansion and mechanical stress from vibrations and impacts, protecting the welded portions from damage.
Solution Approach 2:
The current collectors are designed with flexible connection portions that can bend or deform elastically in response to vibrations and impacts. This flexibility allows the structure to accommodate mechanical stresses without transmitting excessive forces to the welded joints, while maintaining electrical conductivity and structural integrity under high output conditions.
Data Source
AI summary
A battery having an electrode assembly including a first electrode, a second electrode, and a separator between the first and the second electrode, the first electrode having a first portion including an active material extending between a pair of first sides, and a second portion extending between the pair of first sides and exposed beyond the separator, and at least part of the second portion includes an electrode tab; a battery housing having a first opening at a first end and a second end opposite the first end, the battery housing accommodating the electrode assembly; and a first current collector including a support portion on the electrode assembly, a first tab coupling portion extending from the support portion and coupled with the second portion of the first electrode and a first housing coupling portion extending from the support portion and electrically coupled onto an inner surface of the battery housing.