Wound Secondary Battery Cell Notch Structure for Burr Containment
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Solution Overview
Problem
Lithium-ion batteries face challenges in achieving high energy density and safety performance due to burrs formed during the manufacturing process, which can lead to internal short circuits and increased manufacturing costs, particularly due to the use of separate devices for laser cleaning and welding, resulting in high costs and potential safety hazards.
Innovation Solution
A secondary battery cell design that integrates an anode and cathode electrode plate with notches to remove burrs and a winding formation system that combines multiple mechanisms on a single platform for efficient manufacturing, reducing the risk of internal short circuits and improving energy density and safety performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick adhesive tape is stuck in the groove to prevent burrs from piercing the separator, then safety performance is improved, but cell thickness increases causing loss to energy density
Solution Approach 1:
The groove is pre-formed during electrode plate manufacturing to receive and contain burrs before they can cause harm. This preliminary structural preparation eliminates the need for additional protective layers like adhesive tapes, preventing internal short circuits while maintaining cell thickness and energy density.
Solution Approach 2:
The burrs, which are harmful byproducts of laser cleaning, are redirected into the groove structure where they serve a beneficial function by being contained and isolated from the separator. This converts the harmful burrs into a benign situation where they cannot cause internal short circuits.
2Manufacturing precision
If independent laser cleaning device and welding-winding device are used respectively, then manufacturing precision is improved, but device complexity increases and factory buildings occupy large space
Solution Approach 1:
The laser cleaning device, welding device, and winding device are merged into an integrated manufacturing system. The groove is formed and cleaned in-situ during electrode plate production, and the same system proceeds to welding and winding operations, eliminating the need for separate independent devices while maintaining manufacturing precision.
Solution Approach 2:
The manufacturing system is designed with multi-functionality, where a single integrated system performs multiple operations including groove formation, laser cleaning, welding, and winding. This universal system reduces device complexity and factory space occupation while maintaining the precision required for groove cleaning.
3Quantity of substance
If groove is configured on electrode plate and welding is performed in the groove, then energy density is improved, but burrs are formed on the current collector edge causing internal short circuit risk
Solution Approach 1:
The groove structure serves dual purposes: it concentrates the laser energy for precise cleaning to enable high energy density configuration, and simultaneously contains the burrs generated during cleaning within the groove boundaries, preventing them from causing internal short circuits.
Solution Approach 2:
The groove creates a localized region with different functional properties - the bottom area is optimized for laser cleaning and welding operations to achieve high energy density, while the side walls provide containment for burrs. This local differentiation of function resolves the contradiction between energy density improvement and burr management.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively enhances energy density and safety performance by preventing internal short circuits while reducing manufacturing costs and space requirements, as evidenced by improved performance metrics in comparison to conventional methods.
Implementation Method 1
the laser cleaned groove on the electrode plate has an overheated perforation or a burned hole on the edge due to focal length fluctuation and deviation
Data Source
AI summary
A secondary battery cell includes an anode electrode plate, an anode electrode tab, a cathode electrode plate, a cathode electrode tab, and a separator. A winding formation system of the secondary battery cell includes a working platform, a winding mechanism, an anode electrode plate unwinding roller, an anode electrode plate cleaning mechanism, an anode electrode plate die-cutting mechanism, an anode electrode tab supply mechanism, an anode electrode tab connection mechanism, an anode electrode plate convey mechanism, a cathode electrode plate unwinding roller, a cathode electrode plate cleaning mechanism, a cathode electrode plate die-cutting mechanism, a cathode electrode tab supply mechanism a cathode electrode tab connection mechanism, a cathode electrode plate convey mechanism, a first separator unwinding roller, a second separator unwinding roller, a first separator convey mechanism, and a second separator convey mechanism.