Electrochemical Multi-Cell with Integrated Uncoated Tabs
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Solution Overview
Problem
Conventional methods for manufacturing electrochemical storage cells with discrete tabs lead to increased electrical impedance, localized heating, reduced Ah capacity, and higher manufacturing complexity and costs due to the need for coating removal, tab welding, and taping operations.
Innovation Solution
The electrochemical storage multi-cell design features a housing with concentric annular cell chambers and conductive electrolyte filling, where electrode sheets are wound around a cylindrical core with uncoated edges forming tabs that are angularly co-located and integrated into the jellyroll structure, eliminating the need for discrete tab welding and reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discrete tabs are attached to electrode substrates through welding, then electrical connection is provided, but electrical impedance increases and localized heating occurs
Solution Approach 1:
The electrode substrate is divided into multiple uncoated regions along its length, with each region serving as a separate tab attachment point. This segmentation distributes the electrical current across multiple locations rather than concentrating it at single discrete tabs, thereby reducing localized ohmic heating and electrical impedance while maintaining reliable electrical connection.
2Ease of manufacture
If coating removal is performed to expose uncoated regions for tab welding, then tab attachment is enabled, but manufacturing complexity and cost increase
Solution Approach 1:
The electrode substrate is manufactured with uncoated regions pre-formed during the coating process, rather than requiring subsequent coating removal steps. This preliminary action integrates the tab preparation into the base manufacturing process, eliminating separate coating removal, tab welding, and taping operations, thereby reducing manufacturing complexity and cost while enabling efficient tab attachment.
3Reliability
If multiple tabs are increased to decrease cell impedance, then electrical performance improves, but manufacturing complexity increases
Solution Approach 1:
Multiple uncoated regions are integrated directly into the electrode substrate manufacturing process as a unified structure, rather than requiring separate attachment of multiple discrete tabs. This merging approach achieves the electrical performance benefits of multiple connection points while simplifying manufacturing by eliminating separate tab attachment operations, thereby improving electrical performance without increasing manufacturing complexity.
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
This approach results in improved electrical and thermal performance with reduced manufacturing costs and complexity, enabling high-power operation with low impedance connections and lower thermal resistance, while simplifying the manufacturing process by eliminating the need for discrete tab attachment.
Implementation Method 1
conductive electrolyte filling each of the annular cell chambers
Implementation Method 2
electrochemical storage cells, wherein each of the plurality of annular cells are positioned in one of the plurality of annular cell chambers, and the plurality of annular cells are electrically connected in series
Data Source
AI summary
An electrochemical storage multi-cell may comprise: a housing, including a plurality of concentric annular cell chambers; a plurality of electrochemical storage cells, wherein each of the plurality of annular cells are positioned in one of the plurality of annular cell chambers, and the plurality of annular cells are electrically connected in series; and conductive electrolyte filling each of the annular cell chambers.