Rolled Tabless Electrode Cell With Conductive Edge Connection
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Solution Overview
Problem
Current battery cell designs with jelly-roll configurations face increased ohmic resistance due to the distance current must travel through cathode or anode tabs to external connectors, leading to higher costs and manufacturing challenges.
Innovation Solution
A cell design where a conductive material is integrated into the substrate, allowing for a tabless configuration with reduced ohmic resistance by having the conductive portion run along the length of the electrode, connected directly to the can, and a cap with specific features for enhanced connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tabs are used to connect electrodes to external connectors, then electrical connection is achieved, but ohmic resistance increases due to current travel distance
Solution Approach 1:
The patent transitions from a point-contact tab system to a distributed line-contact system by integrating conductive material along the entire length of the electrode. This dimensional change from 0D/2D tab contact to 1D longitudinal contact dramatically reduces the current travel distance and ohmic resistance while maintaining reliable electrical connection.
Solution Approach 2:
The conductive path is segmented into multiple parallel pathways along the electrode length rather than relying on a single tab connection. This segmentation distributes the current flow across multiple locations, reducing the effective resistance and improving overall electrical connectivity.
2Reliability
If tabs are used as additional components for connection, then electrical connectivity is provided, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the electrode substrate and conductive material into a single integrated structure. The conductive material is applied directly to the electrode surface during manufacturing, eliminating the need for separate tab components and their associated assembly steps, thereby reducing manufacturing complexity while maintaining electrical connectivity.
3Reliability
If current travels through tabs to external connectors, then electrical connection is established, but current distribution becomes non-uniform
Solution Approach 1:
The patent applies conductive material with varying properties or concentrations at different locations along the electrode length to optimize local current distribution. This local quality variation ensures uniform current density across the entire electrode surface, preventing hotspots and improving overall performance consistency.
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 design reduces ohmic resistance by 5 to 20 times, minimizes current deviation, and improves heat dissipation, leading to a more uniform current distribution and extended cell lifetime.
Implementation Method 1
a second portion of the first substrate at a proximal end along the width of the first substrate comprises a conductive material
Implementation Method 2
the first substrate, the inner separator, and the second substrate are rolled about a central axis to form a cell
Data Source
AI summary
A cell of an energy storage device with at least one electrode that is tabless, and methods of forming thereof, are described. The cell includes a first substrate having a first coating disposed thereon, wherein a second portion of the first substrate at a proximal end along the width of the first substrate comprises a conductive material. An inner separator is disposed over the first substrate. A second substrate is disposed over the inner separator. The second substrate has a second coating disposed thereon. The first substrate, the inner separator, and the second substrate in a successive manner, the first substrate, the inner separator, and the second substrate are rolled about a central axis.