Cylindrical Cell Core Winding to Reduce Voids and Raise Energy Density
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Solution Overview
Problem
Cylindrical cell batteries or electrochemical cells have lower energy densities due to spaces or gaps formed during construction, limiting their efficiency.
Innovation Solution
Incorporating a winding core that serves as an interconnect or current collector, allowing for tighter winding of cell core components and reducing voids, thereby increasing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional winding methods are used to construct cylindrical batteries, then manufacturing simplicity and mechanical stability are maintained, but energy density decreases due to spaces or gaps formed during construction
Solution Approach 1:
A mandrel is introduced as an intermediary tool during the winding process. The mandrel serves as a temporary support structure that enables tighter winding of electrode layers, reducing gaps and void spaces. After winding, the mandrel is removed, leaving a densely packed cell core with improved energy density while maintaining the simplicity of the overall manufacturing process.
2Quantity of substance
If tighter winding is implemented to reduce gaps and increase energy density, then manufacturing precision requirements increase
Solution Approach 1:
The mandrel acts as a precision-guided intermediary that maintains consistent spacing and alignment during winding. Its structured geometry provides reference surfaces that guide the electrode layers into precise positions, reducing the skill and precision requirements for operators while achieving tighter, more consistent winding with fewer gaps.
Solution Approach 2:
The mandrel is prepared in advance with pre-defined geometric features and spacing elements before the winding process begins. This preliminary preparation establishes the precise winding pattern and spacing requirements, allowing the actual winding operation to proceed with reduced precision demands since the framework is already in place.
Data Source
AI summary
An electrochemical cells and methods of making the same are disclosed. An electrochemical cell may include a cell housing and a cell core. The cell housing may define a tubular cell body extending along a longitudinal axis from a distal end to a proximal end. The cell core may be disposed in the cell housing. The cell core may include a winding core extending along the longitudinal axis, a cathode, an anode, a plurality of inner windings, and a plurality of outer windings. The plurality of inner windings may be coiled around the winding core and define an inner diameter. The plurality of outer windings may be coiled around the plurality of inner windings and define an outer diameter.