Multi-Tab Battery Cell Assembly for Lower Resistance and Heat
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Battery cells face challenges in reducing internal resistance and heat buildup, which limit their power capability, especially in high-demand applications like electrified vehicle traction battery packs.
Innovation Solution
The battery cell design incorporates a plurality of current collector tabs arranged in groupings, which are joined together via crimping or welding to form an enlarged current collector tab, optimizing the surface area and reducing internal resistance and heat buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple current collector tabs are used, then power capability increases, but internal resistance increases
Solution Approach 1:
Multiple current collector tabs are joined together to form a single enlarged current collector tab structure. This merging approach combines the benefits of multiple tabs (increased power capability) while maintaining low internal resistance through the continuous conductive path provided by the joined tabs, eliminating the disadvantage of using separate tabs
2Reliability
If current collector tabs are joined together, then surface area increases reducing internal resistance, but manufacturing complexity increases
Solution Approach 1:
The current collector tabs are joined together during the electrode assembly manufacturing process before the battery cell is sealed. This preliminary action integrates the tab joining step into the existing manufacturing workflow, avoiding the need for separate post-assembly operations and minimizing additional manufacturing complexity
3Power
If multiple current collector tabs are used, then power capability increases, but heat buildup increases
Solution Approach 1:
By merging multiple current collector tabs into a single enlarged tab structure, the current path is consolidated into a larger cross-sectional area. This reduces electrical resistance and consequently reduces I²R heat generation, allowing the battery to handle higher power loads without excessive heat buildup
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 the power capability and reduces internal resistance and heat buildup in battery cells, improving their performance in electrified vehicle traction battery packs.
Implementation Method 1
the current collector tabs of each of the one or more tab groupings are joined together by a crimp
Implementation Method 2
the current collector tabs of each of the one or more tab groupings are joined together by a weld
Implementation Method 3
the weld is an arc weld
Data Source
AI summary
Exemplary battery cell designs, such as those for use within electrified vehicle traction battery packs, for example, may include an electrode assembly that includes a plurality of current collector tabs. The current collector tabs may be arranged in one or more tab groupings when the electrode assembly is positioned in a folded configuration. The current collector tabs of the one or more tab groupings may be joined together to establish an enlarged current collector tab that is larger than any individual one of the current collector tabs of the one or more tab groupings. The enlarged current collector tab is an optimized tab configured to reduce internal resistance, reduce heat buildup, and increase the power capability of the battery cell.