Patterned Crimp for Battery Current Collector Attachment
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Solution Overview
Problem
Traditional methods for fixing current collectors to electrochemical cell jelly rolls are cumbersome and expensive, often requiring additional welding to secure the collectors, which increases manufacturing time and cost.
Innovation Solution
A patterned crimping process using crimping dies with ridges or conical extensions to securely attach current collectors to the jelly roll ends, eliminating the need for welding by creating a secure impression that fixes the collectors in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding methods are used to secure current collectors to jelly rolls, then the attachment strength is improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent removes the welding operation from the manufacturing process by using a pure mechanical crimping attachment method. The crimping dies directly form the attachment between current collector and jelly roll without any welding step, extracting the harmful and time-consuming welding process while maintaining attachment strength through mechanical interlocking.
Solution Approach 2:
The patent replaces the thermal welding system with a mechanical crimping system. Instead of using heat and electricity to join materials, the invention uses mechanical force from crimping dies to deform the current collector and create a secure mechanical interlock with the jelly roll, eliminating the need for welding equipment and processes.
2Strength
If traditional welding methods are used to secure current collectors to jelly rolls, then the attachment strength is improved, but the manufacturing cost increases
Solution Approach 1:
The patent removes the welding operation from the manufacturing process by using a pure mechanical crimping attachment method. The crimping dies directly form the attachment between current collector and jelly roll without any welding step, extracting the harmful and time-consuming welding process while maintaining attachment strength through mechanical interlocking.
Solution Approach 2:
The patent replaces the thermal welding system with a mechanical crimping system. Instead of using heat and electricity to join materials, the invention uses mechanical force from crimping dies to deform the current collector and create a secure mechanical interlock with the jelly roll, eliminating the need for welding equipment and processes.
3Ease of manufacture
If simple crimping without pattern is used, then the manufacturing process is simplified, but the attachment security is insufficient
Solution Approach 1:
The patent applies local quality by introducing patterns (ridges, conical extensions, or combinations) on specific areas of the crimping dies that contact the current collector. These localized patterned features create enhanced mechanical interlocking at critical attachment points while keeping the overall process simple and maintaining other areas of the current collector unchanged.
Solution Approach 2:
The patent uses conical extensions or ridges on the crimping dies that create curved or tapered deformation patterns in the current collector. This curvature in the crimping action creates more effective mechanical interlocking compared to flat, simple crimping, enhancing attachment security through geometric shape transformation.
Data Source
AI summary
A battery module includes an electrochemical cell. The electrochemical cell includes a jelly roll having an anode sheet, a cathode sheet, and a separator rolled together to form the jelly roll. Further, the electrochemical cell includes a current collector. The current collector includes a patterned crimp impression therein that extends into and fixes the current collector to an end of the jelly roll.