Flat-Plate Current Collector Structure for Higher Battery Energy Density
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Solution Overview
Problem
Existing battery units have bent current collectors that increase structural strength but occupy more space, reducing the winding space and energy density when connected to tabs, leading to lower energy storage capacity in high-power devices like electric vehicles.
Innovation Solution
The battery unit design features at least one end of the current collector as a flat plate structure, with the tab covering the flat plate from the outer side after being bent, reducing the space occupied by the connecting structure and increasing the winding space, thereby enhancing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bent current collectors are used to connect tabs, then structural strength is improved, but winding space is reduced
Solution Approach 1:
The current collector is segmented into distinct functional zones: a flat plate structure for tab connection and a bent portion for mechanical strength. This segmentation allows each part to perform its specific function optimally without compromising the other.
Solution Approach 2:
Different parts of the current collector have different geometric properties: the flat plate structure provides a stable mounting surface for tabs, while the bent portion provides structural reinforcement. This local differentiation of quality resolves the contradiction between connection stability and space efficiency.
2Reliability
If bent current collectors are used to connect tabs, then connection stability is improved, but energy density is reduced
Solution Approach 1:
The current collector is divided into a flat plate structure for stable tab connection and a bent portion for structural support. This segmentation ensures connection reliability while minimizing the space consumed by the connecting structure, thereby preserving energy density.
Solution Approach 2:
The geometric parameters of the current collector are optimized: the flat plate provides a large contact area for stable connection, while the bent portion is designed with specific dimensions to provide necessary strength without excessive space occupation. This parameter optimization resolves the contradiction between connection stability and energy density.
3Strength
If more space is allocated to current collector connecting structures, then structural integrity is improved, but overall energy storage capacity is reduced
Solution Approach 1:
The current collector is segmented into a flat plate structure for tab connection and a bent portion for structural integrity. This segmentation ensures that the minimum necessary space is allocated to the connecting structure while maintaining structural integrity, thereby maximizing energy storage capacity.
Solution Approach 2:
The current collector features local quality differentiation: the flat plate structure provides stable connection with minimal space, while the bent portion provides structural reinforcement only where needed. This localized approach to structural enhancement resolves the contradiction between structural integrity and energy storage capacity.
Data Source
AI summary
A battery unit and a battery module, where the battery unit includes an electrode assembly, including a first electrode and a second electrode, which have opposite polarities, each of the first electrode and the second electrode includes a coated portion and an uncoated portion, and the uncoated portion is located at an end part of a coated portion along the length direction of the electrode assembly and forms a tab; two terminals, arranged at the top of the electrode assembly; and two current collectors for electrically connecting the tabs on both sides of the electrode assembly with the terminals on the same side respectively. At least one end of at least one current collector along the width direction of the electrode assembly is a flat plate structure, and the tab covers the flat plate structure from the outer side after being bent.