Tabless Electrode Cell Structure for Lower Ohmic Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current battery cells with jelly-roll designs face increased ohmic resistance due to current traveling through tabs, which also increase costs and manufacturing challenges.
Innovation Solution
A cell design with a conductive portion on the electrode that runs along its length, eliminating the need for tabs and improving electrical contact with the can, reducing ohmic resistance and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tabs are used to connect electrodes to terminals, then electrical connection is achieved, but ohmic resistance increases and manufacturing complexity increases
Solution Approach 1:
The patent removes the tab component entirely from the electrode structure. Instead of using separate tabs to connect electrodes to terminals, the electrode substrate itself is extended and directly connected to the terminal, eliminating the need for additional tab components and reducing manufacturing complexity while maintaining electrical connection reliability
Solution Approach 2:
The patent merges the function of the tab with the electrode substrate by extending the substrate material to serve as both the current collector and the connection element. This integration eliminates the need for separate tab components and reduces the number of assembly steps required during manufacturing
2Reliability
If current travels through tabs to connectors, then electrical connection is established, but ohmic resistance increases due to longer current path
Solution Approach 1:
By removing the tab component and directly connecting the extended electrode substrate to the terminal, the patent shortens the current path from: electrode → tab → connector to electrode → terminal, thereby reducing ohmic resistance and energy loss
Solution Approach 2:
The patent extends the electrode substrate in the spatial dimension along the length of the cell, allowing the substrate to reach directly to the terminal position. This dimensional extension eliminates the need for lateral current travel through tabs and reduces the overall current path length
3Reliability
If tabs are added as additional components, then electrical connection is achieved, but costs increase
Solution Approach 1:
The patent eliminates the tab component from the bill of materials, reducing component count and associated costs. By using only the electrode substrate material for both current collection and terminal connection, the patent reduces material costs and assembly costs
Solution Approach 2:
The patent combines multiple functions (current collection and terminal connection) into a single component (the extended electrode substrate), reducing the total number of parts that need to be manufactured, inventoried, and assembled, thereby reducing overall manufacturing costs
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.