Electrochemical Cell With Layered Electrodes And Pin Conductor
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Solution Overview
Problem
Existing electrochemical cells, particularly button cells, face challenges in maximizing active volume utilization and energy density due to inefficient use of internal space, especially in small form factors required for implants and hearing aids, leading to the need for a more space-saving and cost-effective manufacturing method.
Innovation Solution
The electrochemical cell features a layered electrode structure with mechanically prestressed tabs and a pin conductor system, eliminating the need for internal conductor lugs by using elastic materials and precise mechanical stress to ensure reliable and efficient contact between electrodes and their conductors, allowing for a more compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a winding structure with internal conductors is used, then the battery can be manufactured with conventional methods, but valuable active volume is wasted due to bulky internal conductors
Solution Approach 1:
The invention extracts the internal conductor lugs from the battery structure and replaces them with external conductor elements (housing and pin) that contact the electrode layers from the outside. This eliminates the bulky internal conductors that waste active volume while maintaining electrical connectivity through external contact points.
Solution Approach 2:
The invention transitions from a three-dimensional winding structure with internal conductors to a layered planar structure where conductors contact electrodes from the outside dimensions. This dimensional reorganization allows the electrode layers to extend fully into the active volume without being constrained by internal conductor space.
2Quantity of substance
If electrode layers are made larger to increase active material, then energy density improves, but mechanical contact with conductors becomes unreliable without prestressing
Solution Approach 1:
The invention applies preliminary mechanical prestressing to the electrode layers during assembly, before the battery is sealed and filled with electrolyte. This pre-compression ensures that the electrode layers maintain reliable mechanical contact with the conductor elements throughout the battery's operational life, preventing contact loss due to swelling or shrinkage.
Solution Approach 2:
The invention changes the mechanical parameters of the electrode layers by applying compressive prestress, transforming them from a loose fit to a pre-compressed state. This parameter change ensures continuous reliable contact between the electrode layers and conductors while allowing the electrode dimensions to be optimized for maximum active material content.
3Length of stationary object
If the battery is designed for small overall heights to fit implants and hearing aids, then device miniaturization is achieved, but active volume utilization becomes limited
Solution Approach 1:
The invention adopts a layered planar structure that optimizes the use of radial and axial dimensions rather than relying on height. By stacking electrode layers radially and contacting them from the housing walls and central pin, the design maximizes active volume utilization within the constrained height, allowing thin-profile batteries to achieve high energy density.
Solution Approach 2:
The invention segments the electrode structure into multiple thin layered units stacked radially, each layer contributing to active material content. This segmentation allows the battery to pack more active material into the available volume without increasing overall height, as each layer can be independently optimized and stacked efficiently.
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 configuration enhances energy density by optimizing the use of internal volume, reducing the size of sealing rings, and maintaining mechanical prestress even after electrolyte addition, resulting in a more efficient and cost-effective battery suitable for small devices.
Implementation Method 1
The tabs are formed on the electrode layers and are designed to be elastically deformable in the mounted state with respect to the conductors assigned to the respective electrode layers
Implementation Method 2
Electrochemical cells are used to convert chemical energy into electrical energy
Data Source
Figure 1
Figure 2
Figure 2A~2B
AI summary
The present invention relates to an electrochemical cell with a layered electrode structure, wherein oppositely polarized electrode layers are physically spaced apart from one another by separator layers. The cells comprise a first housing part (2), which defines an inner volume (3) and is configured to simultaneously form a conductor for a first electrode pole. It further comprises a pin (4) which extends from the outside into the inner volume (3) and is configured to form a conductor for a second electrode pole. The cell according to the invention further comprises insulation (7), which electrically insulates the first housing part (2) from the pin (4), and wherein the electrode layers (5.1, 5.2, 5.3 ..., 6.1, 6.2, 6.3 ...) in the inner volume (3) have physical contact with their corresponding conductors, such that a mechanical preload exists between the electrode layers and the corresponding conductor.The present invention further relates to a method for manufacturing an electrochemical cell according to the invention, as well as corresponding uses thereof.