Prismatic Battery Cell Winding with Integrated Welding
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Solution Overview
Problem
The existing methods for producing prismatic battery cells face challenges in efficiently arranging and contacting current collectors within the cell housing, leading to complex production processes and material inefficiencies, particularly due to the need for branched current collectors and coated electrode edges.
Innovation Solution
The method involves arranging the cathode and anode layers spatially parallel to each other and to a winding axis, using a winding board with integrated welding surfaces for contacting current collectors, and employing fewer separator layers to simplify the winding process, reduce material usage, and eliminate unnecessary coating on electrode edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple battery windings are arranged in the cell housing, then the battery capacity increases, but the complexity of current collector arrangement and welding increases
Solution Approach 1:
The battery cell is divided into multiple independent battery windings (first, second, third, and fourth battery windings) that can be separately produced and then assembled in the cell housing. Each winding is a self-contained unit with its own electrode layers and separator layers, allowing for modular assembly that simplifies the overall current collector arrangement while maintaining high capacity
Solution Approach 2:
The patent transitions from a single-layer electrode arrangement to a three-dimensional stacked configuration with multiple battery windings arranged vertically in the cell housing. This spatial arrangement allows multiple windings to coexist without requiring complex planar routing of current collectors, as each winding can be independently contacted from above and below
2Reliability
If current collectors are branched to contact multiple battery windings, then the electrical connection is achieved, but the material usage and production complexity increase
Solution Approach 1:
Each battery winding is equipped with its own dedicated current collectors (first current collector for anode, second current collector for cathode) without requiring branching to other windings. This segmentation eliminates the need for complex branched current collector structures while ensuring reliable electrical connection for each winding unit
Solution Approach 2:
The current collectors serve multiple functions: they provide electrical connection for their respective battery winding, serve as structural support during assembly, and enable independent handling of each winding unit. This multi-functionality reduces the need for additional specialized components
3Reliability
If electrode edges are coated to prevent short circuits, then the safety improves, but the material usage and production complexity increase
Solution Approach 1:
Separator layers are introduced as intermediary components between the cathode and anode layers, physically preventing contact between opposite polarity electrodes. These separator layers eliminate the need for complex edge coatings or insulation treatments on electrode edges, simplifying the manufacturing process while maintaining safety
Solution Approach 2:
The function of preventing short circuits is extracted from the electrode edges themselves and transferred to dedicated separator layers. This separation of functions allows the electrodes to be manufactured without complex edge treatments, as the separator layers handle the insulation function
4Reliability
If multiple separator layers are used, then the short circuit prevention improves, but the material usage increases
Solution Approach 1:
Separator layers are strategically positioned only where needed between cathode and anode layers in the battery winding structure. The number and placement of separator layers are optimized locally based on the specific winding configuration, ensuring adequate short circuit prevention without excessive material usage throughout the entire cell
Data Source
AI summary
A method of producing a prismatic battery cell includes forming an initial arrangement by spatially arranging one or two wiring boards, a cathode layer, an anode layer, and at least two separator layers so as to be in parallel with each other and with respect to a winding axis. The initial arrangement is wound about the winding axis to form a battery winding. The battery winding is inserted in a cell housing, and a respective current connector is connected to each of the cathode layer and anode layer. The cell housing is filled with a liquid electrolyte, and is closed. A prismatic battery cell of this type can be included in a battery, such as a battery included with an automotive vehicle.