Foil Current Collector With Unperforated Tab Strip

Solution Overview

Problem

Conventional current collectors in electrochemical cells lack structural integrity and effective material locking mechanisms, leading to potential delamination and uneven discharge during the life of the cell.

Innovation Solution

A current collector design featuring a perforated pattern that extends to the perimeter edges except for an unperforated strip adjacent to the connector tab, enhancing structural integrity and material locking through perforations, ensuring uniform discharge and preventing sloughing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If an unperforated frame completely borders or surrounds the perforated interior region, then structural integrity at the current collector tab is improved, but electrode active material contact and locking to the current collector is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidelectrode active material contact

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The current collector features a localized unperforated strip only at the upper outer edge adjacent to the connector tab, while all other regions including the perimeter edges contain perforations. This local differentiation provides structural support where needed while maintaining electrode contact across the entire surface area.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The unperforated region is segmented to extend only partially along the upper outer edge rather than forming a complete surrounding frame. This segmentation allows perforations to reach the perimeter edges in most areas, enabling electrode material locking while providing localized structural reinforcement at the tab connection point.

Inventive Principle:

Principle #1Segmentation

2Reliability

If perforations extend to all perimeter edges, then electrode active material locking is improved, but structural integrity at the connector tab is reduced

Engineering Contradiction:

Improveelectrode active material lockingVSAvoidstructural integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The current collector features a localized unperforated strip only at the upper outer edge adjacent to the connector tab, while all other regions including the perimeter edges contain perforations. This local differentiation provides structural support where needed while maintaining electrode contact across the entire surface area.

Inventive Principle:

Principle #3Local quality

3Strength

If a complete unperforated frame surrounds the perforated region, then structural integrity is improved, but discharge uniformity is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoiddischarge uniformity

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The unperforated region is segmented to extend only partially along the upper outer edge rather than forming a complete surrounding frame. This segmentation allows perforations to reach the perimeter edges in most areas, enabling electrode material locking while providing localized structural reinforcement at the tab connection point.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The current collector features a localized unperforated strip only at the upper outer edge adjacent to the connector tab, while all other regions including the perimeter edges contain perforations. This local differentiation provides structural support where needed while maintaining electrode contact across the entire surface area.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11075388B1Foil-type current collector having an unperforated strip at the connector tab

Publication Date: 2021.07.27 GREATBATCH LTD

AI summary

A current collector for an electrochemical cell is described. Unlike conventional current collector designs, the current collector does not have an unperforated perimeter frame completely bordering or surrounding a perforated interior region. Instead, only that portion of the current collector adjacent to the connector tab is unperforated. Otherwise, perforations extend directly to the perimeter edge.