Wound Battery Electrode Notches for Non-Cylindrical Housing
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Solution Overview
Problem
Miniaturized batteries face inefficiencies due to non-cylindrical shapes that create cavities in their housings, leading to reduced energy density and increased production costs, as existing technologies struggle to optimize volume utilization and maintain effective electrode separation.
Innovation Solution
A battery design featuring a housing with indentations, recesses, or bulges that accommodate a wound active band with strategically placed notches and gaps, allowing the band to fill the available volume efficiently while maintaining adequate separation between electrodes, thus optimizing space usage and preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cylindrical winding structure is used, then the battery can be manufactured efficiently with good electrode separation, but the housing shape cannot be adapted to non-cylindrical device requirements, creating cavities and reducing energy density
Solution Approach 1:
The active band is segmented with notches and gaps that allow it to conform to non-cylindrical housing shapes while maintaining the winding structure's manufacturing efficiency. The segmentation enables the band to adapt to rectangular, prismatic, or other non-cylindrical geometries without compromising electrode separation.
Solution Approach 2:
The invention introduces asymmetric features (notches and gaps) in the active band that allow it to adapt to asymmetric non-cylindrical housing shapes. These asymmetric modifications enable the winding structure to fill cavities and conform to device-specific geometries while maintaining efficient manufacturing processes.
2Adaptability or versatility
If the housing shape is adapted to non-cylindrical forms, then device integration is improved, but cavities are created in the housing that reduce energy density per volume
Solution Approach 1:
The active band is modified with local features (notches and gaps) that allow it to conform to the specific geometry of the housing. These local modifications enable the band to fill previously empty spaces and cavities in non-cylindrical housings, maximizing the quantity of active material per volume while maintaining adaptability to different housing shapes.
3Quantity of substance
If the active band is wound to fill non-cylindrical spaces, then volume utilization improves, but electrode separation may be compromised leading to short circuits
Solution Approach 1:
The notches and gaps are pre-designed into the active band before winding, with specific dimensions and positions calculated to ensure adequate electrode separation is maintained even when conforming to non-cylindrical shapes. This preliminary design ensures that volume utilization is maximized without compromising reliability.
Solution Approach 2:
The notches and gaps act as intermediaries that allow the active band to adapt to non-cylindrical geometries while maintaining proper electrode separation. These features serve as buffer zones that prevent short circuits while enabling the band to fill available volume in adapted housing shapes.
Data Source
Figure 1a~2b
Figure 3a~6b
Figure 7~8
AI summary
The invention relates to wound-construction batteries and methods for their manufacture. The battery comprises a housing that defines an active volume V, wherein the active volume V is composed of a base volume U minus at least one indentation volume X and/or minus at least one recess volume Y and/or plus at least one bulge volume Z. It further comprises an active band which, when wound, substantially fills the active volume V and comprises at least one anode layer and at least one cathode layer.The strip has recesses and/or indentations in the longitudinal direction, particularly in the direction in which it is wound up, which are designed such that the recesses and/or indentations lie on top of each other in the wound state of the strip in such a way that a sum of recesses and/or indentations defines a volume P which essentially corresponds to the sum of the indentation volume X and/or the recess volume Y.