Stack-wound Battery with Integral Tabs
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Solution Overview
Problem
Conventional battery designs face challenges in maximizing energy density while maintaining compact size and simplicity of assembly, often requiring additional steps for conductive tab welding that reduce active material coverage and increase battery size.
Innovation Solution
The battery design features patterned anode and cathode collectors with integrally formed conductive tabs, allowing for full coverage with active material and an offset winding configuration that maximizes active surface area, eliminating the need for separate conductive tab welding and enhancing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional battery designs use separate conductive tabs requiring welding, then electrical connection is achieved, but active material coverage is reduced and manufacturing complexity increases
Solution Approach 1:
The conductive tabs are integrally formed with the anode and cathode collectors as a single piece, eliminating the need for separate tabs and welding operations. This merging of components increases active material coverage by removing non-active tab materials and simplifies manufacturing by eliminating the welding step.
2Quantity of substance
If battery size is increased to hold more charge, then energy capacity is improved, but device enclosure space is exceeded
Solution Approach 1:
The battery uses a stack-wound configuration with multiple layers stacked vertically, changing the geometric arrangement from conventional cylindrical to a compact stacked structure. This parameter change in spatial organization allows higher charge capacity within a smaller overall volume, fitting within device enclosure constraints.
3Ease of manufacture
If conventional winding configuration is used, then battery assembly is straightforward, but active surface area is not maximized
Solution Approach 1:
The battery employs an offset winding configuration where the anode and cathode layers are offset relative to each other, creating an asymmetric stacked arrangement. This asymmetric design maximizes the active surface area by ensuring optimal contact and alignment between opposing electrodes, while maintaining relatively simple assembly procedures.
Data Source
AI summary
A battery includes a housing and a laminate in the housing. The laminate includes an anode and cathode, each having a first end and an opposing second end. The anode includes an anode collector including a first sheet of patterned conductive material having a first active area and a first plurality of conductive tabs formed integrally with the first active area, and a first active material on the first active area of the anode collector. The cathode includes a cathode collector including a second sheet of patterned conductive material having a second active area and a second plurality of conductive tabs formed integrally with the second active area, and a second active material on the second active area of the cathode collector. Active material is not on either the first or second plurality of conductive tabs. A separator is positioned between the anode and the cathode.