3D Electrode Secondary Battery Insulation Design
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Solution Overview
Problem
Current secondary batteries face challenges in achieving high energy density and preventing short circuits, particularly due to the exposure of active material layers and collector layers, which can lead to reduced battery lifespan and performance in portable and wearable devices.
Innovation Solution
A high-capacity secondary battery design featuring a 3D electrode structure with insulated outer side surfaces, where first and second collector layers are sized appropriately to prevent exposure and contact, and insulating members are used on lead wires to prevent short circuits, ensuring improved insulation and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a 3D electrode structure is used to increase energy density, then the battery capacity is improved, but the outer side surface of the electrode structure is exposed and can contact with collector layers causing short circuits
Solution Approach 1:
An insulating layer is introduced as an intermediary between the exposed outer side surface of the 3D electrode structure and the collector layers. This insulating layer prevents direct contact between conductive components, eliminating the short circuit risk while preserving the high capacity benefits of the 3D structure.
Solution Approach 2:
A thin film insulating layer is applied to the outer side surface of the 3D electrode structure. This thin film provides effective electrical insulation without adding significant volume or compromising the compact design of the battery.
2Reliability
If collector layers are enlarged to cover the 3D electrode structure, then short circuit prevention is improved, but the battery volume and weight increase
Solution Approach 1:
Instead of enlarging the collector layers, a thin film insulating layer is applied to the outer side surface of the 3D electrode structure. This approach provides effective insulation while maintaining the original compact dimensions of the battery.
Solution Approach 2:
The insulation solution is applied in a different dimension - rather than expanding the horizontal area of collector layers, the insulating layer is applied vertically to the outer side surface of the 3D electrode structure, providing protection without increasing overall battery volume.
Data Source
AI summary
A plurality of unit cells is stacked on each other in a secondary battery, and each of the plurality of unit cells includes first and second collector layers, which are spaced apart from each other, and a 3-dimensional (“3D”) electrode structure provided between the first and second collector layers and having an outer side surface that is externally exposed and insulated, wherein, in the plurality of unit cells, the first collector layers are stacked to face each other and the second collector layers are stacked to face each other.