Recessed Tab for Thinner Battery Current Collectors

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Solution Overview

Problem

Conventional battery manufacturing processes are limited by the need for a minimum thickness of the current collector layer to ensure mechanical stability, reduce Equivalent Series Resistance (ESR), and maintain solderability, which restricts the thickness and thus the energy density of batteries.

Innovation Solution

The active material layer is stabilized independently of the current collector layer, allowing for a thinner current collector layer by forming a recess in the active material layer to receive the tab element, and using a temporary backing substrate for mechanical stabilization, enabling a more compact and efficient battery design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the current collector layer is made thinner to increase energy density, then the battery capacity per unit volume increases, but the mechanical stability and solderability of the battery deteriorate

Engineering Contradiction:

Improveactive material content per unit volumeVSAvoidmechanical stability of current collector layer

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

A recess is introduced as an intermediary structural feature in the active material layer. This recess provides mechanical support and stabilization to the tab element without requiring a thicker current collector layer, thus enabling thinner current collectors while maintaining structural stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The solution moves from a two-dimensional planar structure to a three-dimensional structure by forming a recess (depth dimension) in the active material layer. This vertical dimension provides mechanical support without increasing the horizontal footprint, allowing thinner current collectors while maintaining stability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Quantity of substance

If the current collector layer is made thinner to increase energy density, then the battery capacity per unit volume increases, but the Equivalent Series Resistance (ESR) increases

Engineering Contradiction:

Improveactive material content per unit volumeVSAvoidEquivalent Series Resistance (ESR)

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The recess acts as a mediator that improves the electrical connection between the tab element and the current collector layer. By providing a mechanically stable interface within the recess, electrical contact is enhanced, which helps maintain lower ESR even with thinner current collector layers.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Quantity of substance

If the current collector layer is made thinner to increase energy density, then the battery capacity per unit volume increases, but the solderability of the tab element deteriorates

Engineering Contradiction:

Improveactive material content per unit volumeVSAvoidsolderability of tab element

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The recess provides an intermediary platform that enhances the soldering process. The recess structure allows for better access and contact during soldering operations, compensating for the reduced thickness of the current collector layer and maintaining good solderability.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Stability of the object's composition

If conventional battery manufacturing processes are used with minimum thickness current collector layers, then mechanical stability is maintained, but energy density is limited

Engineering Contradiction:

Improvemechanical stabilityVSAvoidenergy density

Core Design Contradiction:

Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

The invention transitions from a flat two-dimensional current collector structure to a three-dimensional structure with a recess. This additional vertical dimension provides mechanical support and stability without requiring increased material thickness, thereby enabling higher energy density while maintaining stability.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The current collector structure is segmented into distinct regions: the main current collector layer and the recessed area. This segmentation allows the recess to provide localized mechanical support where needed (at the tab connection point) while the rest of the current collector can be made thinner to increase energy density.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS10446828B2Recessed tab for higher energy density and thinner batteries

Publication Date: 2019.10.15 MALIKIE INNOVATIONS LTD

AI summary

Various embodiments are described herein for an electrode assembly for a battery and a method of making the electrode assembly. The electrode assembly comprises an active material layer having a recess formed therein at an outer surface of the active material layer, the recess extending from a side facet of the active material layer toward an interior portion of the active material layer; a current collector layer supported on and in electrical contact with the outer surface of the active material layer; and a tab element supported partially within the recess and in electrical contact with at least one of the active material layer and the current collector layer, the tab element being adapted to provide an electrical connection for the electrode assembly.