Secondary Battery Electrode Reinforcement for Crack-Tolerant Conductivity

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Solution Overview

Problem

Secondary batteries experience cracks in electrodes due to volume expansion during charge and discharge cycles, leading to reduced electron mobility, increased resistance, and potential fire risks.

Innovation Solution

A secondary battery design incorporating a reinforcing layer with a conductive layer covering the tab and current collector to maintain electron migration paths even when cracks form, using materials like stainless steel, conductive polymers, and carbon nanotubes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a conventional electrode structure is used, then the battery can be manufactured with simple structure, but cracks are generated in the electrodes due to volume expansion during charge and discharge cycles

Engineering Contradiction:

Improveelectrode structureVSAvoidelectrode integrity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent applies composite materials by combining the current collector with a reinforcing layer made of conductive material. This composite structure provides both the functional properties of the current collector and the mechanical strength of the reinforcing layer, preventing crack formation while maintaining electrical conductivity. The reinforcing layer acts as a structural support that compensates for the volume expansion stress during charge and discharge cycles.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The reinforcing layer is implemented as a thin film structure that covers the current collector. This thin film provides mechanical reinforcement and crack prevention while maintaining flexibility to accommodate the volume changes during electrochemical reactions. The thin film structure ensures that the reinforcement does not interfere with the electrochemical performance of the electrode.

Inventive Principle:

Principle #30Flexible shells and thin films

2Quantity of substance

If the electrode undergoes volume expansion during charge and discharge, then the battery capacity is improved, but continuous stress causes cracks to be generated in the electrodes

Engineering Contradiction:

Improvebattery capacityVSAvoidelectrode strength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The reinforcing layer is applied beforehand to the current collector to provide preemptive mechanical support. This pre-reinforcement structure cushions the electrode against the stress of volume expansion during charge and discharge cycles, preventing crack formation before they can occur. The reinforcing layer absorbs and distributes the mechanical stress, protecting the electrode structure.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If cracks are generated in the electrodes, then the manufacturing process is simplified, but electron migration path is disconnected causing increased resistance

Engineering Contradiction:

Improveelectrode manufacturingVSAvoidelectron conductivity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The reinforcing layer serves multiple functions simultaneously: it provides mechanical strength to prevent cracks, maintains the structural integrity of the electrode, and ensures continuous electron migration paths. By covering the current collector, the reinforcing layer acts as both a structural support and an electrical conductor, addressing both mechanical and electrical requirements in a single component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If the tab is attached to the current collector, then the electrical connection is established, but the tab region is vulnerable to cracks due to stress concentration

Engineering Contradiction:

Improveelectrical connectionVSAvoidstress concentration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The reinforcing layer provides localized reinforcement specifically at the tab attachment region where stress concentration occurs. This local quality enhancement addresses the specific vulnerability of the tab region without requiring reinforcement of the entire electrode structure. The reinforcing layer distributes the stress away from the tab attachment point, preventing crack initiation in this critical area.

Inventive Principle:

Principle #3Local quality

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 design maintains output power and reduces the risk of fire by ensuring efficient electron conductivity despite cracks in the electrodes.

Implementation Method 1

the reinforcing layer includes a conductive layer comprising a conductive material

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20250246773A1Secondary battery

Publication Date: 2025.07.31 SAMSUNG SDI CO LTD

AI summary

Disclosed is a secondary battery capable of maintaining electron mobility when cracks are formed in an electrode of the secondary battery. The secondary battery includes a current collector, an active material layer formed on a portion of the current collector, a tab attached to another portion of the current collector, and a reinforcing layer disposed on the current collector while covering at least a portion of the tab, The reinforcing layer includes a conductive layer comprising a conductive material.