Collector plate for energy storage device and methods of manufacturing
This disclosure provides collector plates for an energy storage device, energy storage devices with a collector plate, and methods for manufacturing the same. In one aspect, a collector plate includes a body. One or more apertures extend into the body. The apertures are configured to allow a portion of a free end of a spirally wound current collector of a spirally wound electrode for an energy storage device to extend into the one or more apertures.
1. An energy storage device, comprising:
an electrode comprising a current collector, the current collector comprising a plurality of laterally spaced layers forming a free end;
a container configured to receive the electrode and an electrolyte; and
a collector plate comprising a body with two or more apertures, a first support member extending between two adjacent apertures of the two or more apertures, and a second support member extending around the two or more apertures and the first support member, the two or more apertures extending into a lower surface of the body, and configured to provide flow through the body, wherein a first portion of the free end of the current collector extends into the two or more apertures when the current collector is pressed against the collector plate.
2. The energy storage device of claim 1 , wherein the first support member comprises at least four spokes extending from a central portion of the body; the body further comprising the second support member comprising an outer ring, wherein the two or more apertures comprise at least four apertures positioned between the spokes.
3. The energy storage device of claim 1 , wherein the second support member comprises a ring extending around the two or more apertures.
4. The energy storage device of claim 1 , wherein the apertures have a total cross-sectional area greater than or equal to approximately 10% of the overall area within a perimeter formed around a bottom surface of the body.
5. The energy storage device of claim 1 , wherein the electrode comprises a spirally wound electrode.
6. The energy storage device of claim 1 , wherein the energy storage device comprises a capacitor.
7. The energy storage device of claim 1 , further comprising the electrolyte.
8. The energy storage device of claim 1 , wherein the collector plate further comprises at least one protrusion extending from the lower surface of the body, each protrusion configured to penetrate the free end of the current collector when the current collector is pressed against the collector plate.
9. The energy storage device of claim 8 , wherein each protrusion forms a perimeter around a corresponding aperture of the two or more apertures.
10. The energy storage device of claim 8 , wherein the at least one protrusion extends approximately orthogonally from the lower surface of the body.
11. The energy storage device of claim 1 , wherein the first portion of the free end of the current collector extends completely through the body.
12. The energy storage device of claim 1 , wherein the first portion of the free end of the current collector includes a body engagement section that extends into the two or more apertures, and engages an inner surface of the body.
13. The energy storage device of claim 12 , wherein the body engagement section extends completely through the body, and engages an upper surface of the body.
14. The energy storage device of claim 1 , wherein a portion of the lower surface of the body contacts a second portion of the free end of the current collector when the first portion of the free end of the current collector extends into the two or more apertures.
15. The energy storage device of claim 14 , further comprising a weld to attach the collector plate to the second portion of the free end of the current collector.
16. The energy storage device of claim 1 , further comprising a sidewall extending from the second support member around at least a portion of the electrode.
17. A method of manufacturing an energy storage device, comprising:
providing an electrode comprising a current collector, the current collector comprising a plurality of laterally spaced layers forming a free end;
providing a collector plate comprising a body with two or more apertures extending into a lower surface of the body, a first support member extending between two adjacent apertures of the two or more apertures, and a second support member extending around the two or more apertures and the first support member; and
pressing the collector plate against the electrode, such that a first portion of the free end of the current collector extends into the two or more apertures.
18. The method of claim 17 , wherein pressing comprises engaging the first portion of the free end with an inner surface of the body.
19. The method of claim 17 , wherein pressing comprises pressing the collector plate against the electrode such that the first portion of the free end extends completely through the thickness of the collector plate.
20. The method of claim 19 , wherein pressing comprises engaging the first portion of the free end with an upper surface of the body.
21. The method of claim 17 , wherein pressing comprises flattening a second portion of the free end of the current collector against the lower surface of the body.
22. The method of claim 21 , wherein flattening comprises reducing the height of the free ends by an amount greater than or equal to approximately 60%.
23. The method of claim 21 , further comprising attaching the second portion of the free end to the collector plate.
24. The method of claim 23 , wherein attaching comprises welding.
25. The method of claim 17 , wherein pressing comprises pressing the collector plate against the electrode, such that a protrusion extending from a lower surface of the body penetrates the first portion of the free end.
26. The method of claim 17 , further comprising inserting the electrode into a container, and filling the container with electrolyte, wherein filling comprises impregnating the electrode with electrolyte in less than 15 minutes.