Rolled Cylindrical Cell Tab Coupling for Fast-Charge Heat Control
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Solution Overview
Problem
Current fast charging electrical vehicle charging systems face inefficiencies in high throughput charging, particularly in aligning and coupling cathode and anode tabs in electrochemical cells, leading to increased costs and heat differentials.
Innovation Solution
The implementation of a winded stack configuration with aligned cathode and anode tabs, coupled in parallel using electrical couplers, simplifies the alignment and coupling process before winding, reducing costs and heat differentials, and enhancing the electrochemical cell's performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional charging systems are used for fast charging electrical vehicles, then charging infrastructure is simpler, but charging throughput is insufficient and efficiency is reduced
Solution Approach 1:
The charging system is segmented into multiple independent charging ports (first charging port, second charging port, etc.) that can operate simultaneously. Each port has its own charging circuit and control logic, allowing parallel charging operations to increase overall throughput while maintaining manageable complexity at each individual port level.
Solution Approach 2:
The system transitions from single-dimensional sequential charging to multi-dimensional parallel charging by adding spatial dimension (multiple ports) and operational dimension (simultaneous charging operations). This dimensional expansion enables higher throughput without proportionally increasing system complexity.
2Speed
If charging speed is increased for fast charging, then charging time is reduced, but heat generation increases causing thermal management issues
Solution Approach 1:
The charging current is segmented and distributed across multiple parallel charging ports and multiple battery electrode tabs (cathode tabs and anode tabs). This segmentation of current pathways reduces current density at any single point, thereby reducing localized heat generation and temperature differentials while maintaining high overall charging speed.
Solution Approach 2:
The system implements localized thermal management by providing cooling channels between specific battery components (e.g., between the stack and housing, or between individual cell groups). This localized cooling approach addresses hot spots at their source, enabling higher charging speeds without excessive heat buildup.
3Quantity of substance
If multiple battery components are integrated to increase capacity, then energy storage is improved, but alignment precision of tabs decreases leading to coupling errors
Solution Approach 1:
Multiple cathode tabs are merged into a single common cathode tab structure, and multiple anode tabs are merged into a single common anode tab structure. This merging approach maintains the electrical capacity benefits of multiple tabs while simplifying the alignment requirement to a single reference point, thereby improving manufacturing precision and reducing coupling errors.
Solution Approach 2:
A common tab structure serves as an intermediary element that connects multiple individual tabs. This intermediary provides a unified alignment reference and mechanical support, ensuring precise electrical coupling while accommodating the increased capacity provided by multiple parallel battery components.
4Manufacturing precision
If complex tab alignment and coupling processes are used to improve precision, then manufacturing accuracy is improved, but production cost increases
Solution Approach 1:
Multiple tabs are merged into common tab structures that can be aligned and coupled in fewer steps. This reduces the number of alignment operations required from multiple individual tab couplings to a smaller number of common tab couplings, thereby improving precision while reducing manufacturing complexity and cost.
Solution Approach 2:
Tabs are pre-aligned and pre-positioned during the stacking process before the winding operation. This preliminary alignment action ensures that when components are assembled, the tabs are already in correct positional relationship, eliminating the need for complex post-assembly alignment procedures and reducing manufacturing costs.
Data Source
AI summary
An electrochemical cell that includes (i) a cathode tabs electrical coupler; (ii) an anode tabs electrical coupler; and (iii) a stack that is rolled about an axis, wherein the stack includes multiple instances of: (a) a cathode sheet; (b) a cathode tab that extends from the cathode sheet at a first direction; (c) an anode sheet, (e) an anode tab that extends from the anode sheet at a second direction, the second direction differs from the first direction; and (f) one or more separator sheets. Multiple cathode tabs of the multiple instances are coupled in parallel to each other by the cathode tabs electrical coupler. Multiple anode tabs of the multiple instances are coupled in parallel to each other by the anode tabs electrical coupler.