Perforated Current Collector Bond Layer for Compact Battery Stacks
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Solution Overview
Problem
The increasing functionality of electronic devices demands higher energy density in battery cells, while size and weight constraints limit the number and size of battery cells, necessitating a solution to maximize energy density and minimize device thickness.
Innovation Solution
A battery cell stack configuration using a perforated current collector with electrically conductive adhesive in its apertures to electrically couple adjacent battery cells, reducing the number and size of current collectors and eliminating a separate bonding layer, thereby increasing volumetric energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional solid current collectors with separate bonding layers are used, then electrical connection and mechanical bonding are achieved, but device thickness and weight increase
Solution Approach 1:
The patent combines the current collector and bonding layer into a single integrated component. The current collector is formed with recesses that directly receive and bond to the electrode, eliminating the need for a separate bonding layer. This merging of functions reduces the number of components, decreases weight, and simplifies the overall structure while maintaining reliable electrical and mechanical connections.
Solution Approach 2:
The current collector is designed to perform multiple functions simultaneously: it provides electrical conduction, mechanical bonding, and structural support. By integrating the bonding function directly into the current collector structure through the recesses, the component achieves multi-functionality, reducing the need for additional specialized layers or components.
2Reliability
If multiple separate components (current collector + bonding layer) are used, then reliable electrical and mechanical connection is achieved, but volumetric energy density decreases
Solution Approach 1:
The integration of bonding functionality into the current collector itself eliminates the volume occupied by separate bonding layers. The recesses in the current collector provide direct bonding contact with the electrode, achieving reliable mechanical and electrical connection without requiring additional material volume, thereby increasing volumetric energy density.
3Ease of manufacture
If conventional current collectors without apertures are used, then manufacturing simplicity is maintained, but thermal expansion accommodation and bonding surface area are limited
Solution Approach 1:
The current collector incorporates apertures or recesses that create a porous-like structure. These openings allow the current collector to accommodate thermal expansion of the electrode material while maintaining structural integrity. The apertures provide space for expansion and contraction, improving reliability under thermal cycling conditions.
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 allowing for a more compact design, accommodating thermal expansion, and providing a reliable interconnect, thus addressing the constraints of size and weight in electronic devices.
Implementation Method 1
an electrically conductive adhesive disposed in each aperture of the plurality of apertures
Implementation Method 2
electrically conductive adhesive disposed in each aperture
Data Source
AI summary
A battery including a first battery cell, a second battery cell, a current collector electrically connected between the first and second battery cells, where the current collector may define a plurality of apertures, and an electrically conductive adhesive disposed in each aperture of the plurality of apertures.