The present invention claims priority to non-provisional application Ser. No. 17/064,243 filed 6 Oct. 2020 by instant inventor, entitled ELECTRIC VEHICLE BATTERY PACKS COMPRISING TABLESS/MULTI-TAB CYLINDRICAL JELLY-ROLL STYLE BATTERY CELLS, which claims priority to non-provisional application Ser. No. 17/033,853 filed 27 Sep. 2020 by instant inventor, entitled ELECTRIC VEHICLE SAFETY AS TO SIDE COLLISIONS AND BATTERY PACK PLACEMENT IN MANUFACTURING, which claims priority to non-provisional application Ser. No. 16/867,273 filed 5 May 2020 by instant inventor regarding vehicle safety, entitled A METHOD AND SYSTEM FOR MITIGATING ANTICIPATED RISKS IN SELF-:DRIVING VEHICLES Lk USE OF MALICIOUS ROADWAY FALSIFIED APPEARANCES now issued U.S. Pat. No. 10,800,434 of 13 Oct. 2020, which claims priority to provisional application Ser. No. 62/298,6682 filed Mar. 7, 2020, hereby incorporated in their entirety at least by reference.
The present invention generally relates to batteries. More specifically, present invention relates to overlap configurations of electrode extensions in battery.
In a preferred embodiment, a battery cell includes a first substrate electrode having a first coating disposed thereon, wherein a second portion of the first substrate electrode comprises a conductive material at a proximal end along the width of the first substrate electrode. An inner separator is disposed over the first substrate. A second substrate is disposed over the inner separator. The second substrate electrode 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 in a jelly roll style of battery configuring.
In a preferred embodiment, said first substrate electrode forms one of an anode and a cathode and the second substrate electrode forms another of the anode and the cathode. In a preferred embodiment, said jelly roll style battery comprises an energy storage device comprising a can comprising a first end and a second end. The first end comprises a first cap comprising an interior contact surface wherein the conductive material of a plurality of extensions of one substrate electrode are in electrical contact with the said first cap in contact area of interior surface. In a preferred embodiment, said electrical contact of the first cap to the said first substrate electrode extensions comprises at least partially overlapped extensions of said first substrate electrode. The term ‘overlap’ as herein defined, has a verb meaning: ‘to extend over and cover at least partly’; and a noun meaning: ‘a part or amount which overlaps’.
In a preferred embodiment, said at least partially overlapped extensions are configured wherein the said overlap enables mitigation of heat during battery operations by enabling multiple electron pathways. In a preferred embodiment, said mitigation of battery heat comprises relatively short average electron path in battery, s as less than 70 mm. In a preferred embodiment, at least one electron path comprises electrons passing from a first overlapped extension, thence via the said overlapping extension, and thence to the cap.
In a preferred embodiment, the extensions can be said to have an end near the cap and an opposite end near the origin of the extension from the electrode sheet. In a preferred embodiment, an overlapped portion formed by at least two extensions is comprised at least near the cap contact end of the respective extensions, as opposed to the origin ends. In a preferred embodiment, the extensions are non-overlapped in the proximal ‘near-to-origin-at-sheet’ aspect, but at least partially overlapped at their parts near to contact area of the cap.
In a preferred embodiment, an effective electrical connection occurs respectively between overlapped electrode extensions and the cap, including in the area wherein the overlap is present. In a preferred embodiment, the cap contact to extension is at least one of: direct or indirect.
In a preferred embodiment, the direct contact is extension physically contacting the cap, and the indirect contact comprises an electron path from overlapped extension to at least one overlapping extension and thence to cap. In a preferred embodiment, the ease of initiation and maintenance of such effective electrical connection pathways set is a function of the configuration of the components.
The cap battery-interior-facing surface configuration and the at least partial overlap of extensions of electrode at the cap-contact location, these mutually enable rapid establishment of said effective electrical connection via multiple electron pathways. In a preferred embodiment, such rapid establishment is enabled by plurality of overlapped electrode extensions comprising an end plate of ‘jelly-roll’ of battery materials.
Said end plate in contact to cap establishes multiple electron pathways, a benefit in keeping battery from overheating. In a preferred embodiment, no additional expenditure of time or connecting materials is needed to establish electrical connection beyond snugly pressing together said end plate and cap interior and securing them in place. Thus, high-speed manufacture of batteries is enabled, defined as one line of production producing at least 200 batteries per hour.
In a preferred embodiment, the high-speed manufacturing enablement comprises winding of ‘jelly-roll’ while progressive folding down electrode extensions during winding. This leads to an end plate of flat to smoothly concave surface, comprising folded-down partially overlapped extensions.
In a preferred embodiment, said end plate maintains its shape at least in part due to the snugness of extension overlapping. Such a flat end plate surface enables establishment of efficient electrical contact between extensions and cap. When ‘jelly-roll’ battery materials are slid into battery can, said flat end plate surface more readily accepts toothed contact at cap contact points. In a preferred embodiment, such enablement of overlapped extensions to make and maintain a flat end plate supports high-speed battery manufacture.
Other features and advantages of the present invention will become apparent when the following detailed description is read in conjunction with the accompanying drawings, in which:
In
In a preferred embodiment, a plurality of electrode extensions comprises tabs, each separated from each other at origin by at least a narrow notch. The notches in another embodiment can vary from narrow to wide. The extensions can be smaller width, such as for extensions destined to be nearer the axis of winding. The extensions can be configured to be wider in parts of the substrate electrode destined to be further from the central axis of winding. The extensions can be rectangular as illustrated, or the extensions can be shaped in non-linear sides and non-regular widths. The extensions can be of same length, as illustrated, or the extensions can be configured with some extensions longer than others.
In
For electron path starting as transiting the middle extension (203), the path can be described as from middle to top extension (201) and then into cap. The configurations of the multiple electron paths of instant invention is key to heat mitigation in the instant battery. By electrons having relatively shorter average electron paths to use within the battery, at least as compared to a single tab configuration, the instant invention battery comprises efficient heat mitigation. Rapid charging is less likely to overheat the battery.
In a preferred embodiment, the instant invention comprises at least one electrode extension separated, at least partially from battery cap interior, by at least one intervening electrode extension. The configurations of the instant invention herein disclosed tend to enable contact easily for batteries as they are assembled. Thus, the instant invention configurations enable high-speed battery manufacturing.
It is understood that the overlap of extensions need not be side over side, as drawn in
It is understood that where a first extension has an intervening overlapping extension separating it from a first contact point at battery cap, said same first extension may have direct contact to a second contact point of battery cap surface. In other words, one electrode extension can contact multiple areas of interior of cap surface. Some of these contacted areas by the electrode extension may have at least partial intervening overlap of extension. Others may not.
In
Although the invention has been described in considerable detail in language specific to structural features, and or method acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as exemplary preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated and can be made without departing from the spirit and scope of the invention.
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
Number | Date | Country | |
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62986682 | Mar 2020 | US |
Number | Date | Country | |
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Parent | 17064243 | Oct 2020 | US |
Child | 17092035 | US | |
Parent | 17033853 | Sep 2020 | US |
Child | 17064243 | US | |
Parent | 16867273 | May 2020 | US |
Child | 17033853 | US |