Sealed Energy Storage Cell Layout for Lower Dead Volume
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Solution Overview
Problem
Existing lithium-ion energy storage cells have inefficiencies in energy density due to dead volumes and internal resistance, particularly in cylindrical round cells, which affect their performance in high-energy applications like electric vehicles and tools.
Innovation Solution
The design features an air- and liquid-tight sealed housing with a metallic cup-shaped housing part and a lid assembly that includes a terminal pole, an electrode-separator assembly with flat terminal end faces, and a contact sheet metal member for efficient electrical connection, minimizing dead volumes and internal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If cylindrical round cells are used for high-energy applications, then energy density is improved, but dead volumes and internal resistance increase
Solution Approach 1:
The cell is divided into a modular assembly comprising a stack of electrode-separator assemblies arranged in alternating sequence, allowing efficient space utilization and reduced dead volumes while maintaining high energy density
Solution Approach 2:
The invention transitions from traditional radial current collection to a planar/dimensional approach with flat terminal end faces and sheet metal contact members, enabling more efficient electrical connection and reduced internal resistance
2Ease of manufacture
If traditional electrode-separator assemblies are used, then manufacturing is simplified, but dead volumes reduce energy density
Solution Approach 1:
Multiple electrode-separator assemblies are merged into a compact stack arrangement with flat terminal end faces, eliminating dead volumes and improving energy density while maintaining manufacturing simplicity through standardized assembly processes
Solution Approach 2:
The invention replaces curved cylindrical electrode arrangements with flat planar surfaces and rectangular geometries, maximizing space utilization and eliminating dead volumes that would otherwise reduce energy density
3Reliability
If complex terminal connections are used, then electrical connection is improved, but device complexity increases
Solution Approach 1:
The complex internal terminal connection structure is extracted and replaced with simple flat terminal end faces and sheet metal contact members, reducing device complexity while maintaining reliable electrical connection through direct contact
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 enhances energy density and safety while allowing for efficient integration into cell groups, with improved thermal management and reduced internal resistance, making it suitable for high-energy applications.
Implementation Method 1
Electrochemical energy storage elements can convert stored chemical energy into electrical energy by virtue of a redox-reaction
Implementation Method 2
This ion current crosses the separator and is made possible by an ion-conducting electrolyte
Implementation Method 3
The terminal pole sits directly on the contact sheet metal member and is connected to it by welding
Data Source
AI summary
An energy storage element includes a sealed housing and an electrode-separator assembly disposed therein. The housing includes a metallic cup-shaped housing part having a housing bottom, a circumferential side wall, and a terminal opening, and a lid assembly closing the terminal opening of the cup-shaped housing part. One edge of an anode current collector or of a cathode current collector is electrically connected to the housing bottom and another edge is electrically connected to a contact sheet metal member which is directly seated on this edge. The lid assembly includes a metallic cover plate and a terminal pole which is guided through an aperture in the cover plate and is electrically insulated from the cover plate. The terminal pole is seated directly on the contact sheet metal member and is connected thereto by welding. Furthermore, the terminal pole is electrically insulated from the cover plate by a cured potting compound.