Tabless Battery Cell with Interleaved Electrode Flags
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Solution Overview
Problem
Current battery cell designs with jelly-roll configurations face increased ohmic resistance and manufacturing challenges due to the need for cathode and anode tabs, which also add thickness and cost.
Innovation Solution
The method involves forming a series of flags at the ends of the electrodes, which are then folded over to create an interleaved 'flower' or 'artichoke' shape, allowing direct electrical connection to current collectors without tabs, thereby eliminating the need for external tabs and reducing resistance and manufacturing complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tabs are used to connect electrodes to terminals in jelly-roll battery design, then electrical connection is achieved, but ohmic resistance increases due to current traveling distance
Solution Approach 1:
The patent divides the single tab connection into multiple distributed flag connections along the electrode length. The electrode includes multiple flags extending from the rolled structure, creating multiple parallel current paths that reduce the effective current travel distance and distribute the electrical connection points throughout the battery cell, thereby reducing ohmic resistance.
Solution Approach 2:
The patent transitions from a two-dimensional tab connection at the electrode end to a three-dimensional distributed flag structure that extends radially outward from the rolled electrode. This dimensional change allows current collection at multiple spatial locations and angles, reducing the current path length through the electrolyte and improving electrical connection efficiency.
2Reliability
If tabs are added as separate components for current collection, then electrical connection is enabled, but device thickness increases
Solution Approach 1:
The patent merges the current collection function directly into the electrode structure itself by forming flags as integral portions of the electrode foil. The flags are created by cutting slits in the foil and folding portions back, eliminating the need for separate tab components and reducing overall device thickness while maintaining electrical connection functionality.
Solution Approach 2:
The patent extracts the unnecessary tab component from the battery design and replaces it with integrated flags formed directly from the electrode material. This extraction eliminates the additional thickness that would be required for separate tabs and their associated connection hardware.
3Reliability
If tabs are included as additional components for current collection, then electrical connection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent implements self-service by having the electrode structure create its own current collection flags through a simple slit-cutting and folding process. The flags are formed directly from the electrode foil itself, eliminating the need for separate tab components and their associated assembly steps, thereby simplifying manufacturing and reducing cost.
Solution Approach 2:
The patent combines the electrode and current collection components into a single integrated structure. The flags are formed as integral parts of the electrode foil through cutting and folding operations, eliminating the need for separate tab components and their associated assembly steps, thereby simplifying manufacturing and reducing cost.
4Reliability
If traditional tabs are used for current collection, then electrical connection is achieved, but the number of components and assembly steps increase
Solution Approach 1:
The patent extracts and eliminates the separate tab component from the battery design, replacing it with integrated flags formed directly from the electrode material. This reduces the total number of components and simplifies the assembly process by eliminating tab attachment steps.
Solution Approach 2:
The electrode structure performs its own current collection function through self-formed flags, eliminating the need for separate tab components and their associated assembly steps. The flags are created through simple cutting and folding operations that are easily integrated into existing electrode manufacturing processes.
Data Source
AI summary
Energy storage devices and methods of manufacturing thereof, such as a lithium ion battery, without tabs connecting the electrode jellyroll to the can are described. A series of flags may be cut, bent and interleaved over one another to create a connection point for upper and lower collector plates within a can. The upper and lower collector plates may be welded directly to the interleaved flags to create connection points for the anode and the cathode within the energy storage device.