Jelly-Roll Battery Electrode Layout for Flat Current Distribution

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Solution Overview

Problem

Lithium batteries face issues with poor interface flatness affecting current density distribution and the use of 1,3-propanesultone as a film-forming additive, which is carcinogenic and increases manufacturing costs.

Innovation Solution

A battery design with a specific electrode assembly structure and electrolytic solution composition using film-forming additives like vinylene carbonate, halogenated carbonate, and lithium difluorophosphate, along with fillers to improve internal structure flatness and even current density distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If 1,3-propanesultone is used as a film-forming additive in the electrolytic solution, then film formation on electrodes is improved, but manufacturing costs increase significantly and carcinogenic substances are present

Engineering Contradiction:

Improvefilm formation qualityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the chemical composition parameters of the electrolytic solution by replacing 1,3-propanesultone with alternative film-forming additives such as vinylene carbonate, fluoroethylene carbonate, and lithium difluorophosphate. This substitution maintains the film-forming function while eliminating carcinogenic substances and reducing manufacturing costs

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs cost-effective film-forming additives that can be used in standard concentrations without requiring expensive specialized materials. The selected additives provide sufficient film formation performance at lower costs compared to 1,3-propanesultone

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If 1,3-propanesultone is used as a film-forming additive in the electrolytic solution, then film formation on electrodes is improved, but carcinogenic substances are present in the battery

Engineering Contradiction:

Improvefilm formation qualityVSAvoidcarcinogenic substance presence

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes the carcinogenic substance 1,3-propanesultone from the electrolytic solution composition. By eliminating this harmful component and replacing it with safe alternatives, the patent maintains film-forming functionality while removing carcinogenic risks from the battery system

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the challenge of removing carcinogenic substances into a benefit by selecting alternative additives that not only eliminate harm but also improve overall battery performance, including cycle life and high-temperature storage stability

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Quantity of substance

If jelly-roll battery cell structure is used, then battery energy density is improved, but interface flatness becomes poor affecting current density distribution

Engineering Contradiction:

Improveenergy densityVSAvoidinterface flatness

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent applies local quality improvement by introducing filler substances at specific locations within the battery package. These fillers are positioned in regions where interface flatness deficiencies occur, providing localized compensation without altering the overall jelly-roll structure or energy density

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite material strategy by combining the jelly-roll electrode structure with additional filler materials. This composite approach maintains the high energy density benefits of the rolled structure while adding materials that improve interface flatness and current density distribution

Inventive Principle:

Principle #40Composite materials

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

Enhances film formation on electrodes, stabilizes the SEI film, and improves battery performance by ensuring consistent and stable current density distribution, while reducing the use of carcinogenic substances.

Implementation Method 1

film formation on negative positive electrodes

Methodology Applied

Scientific EffectFilm formation: Deposition (physical)

Implementation Method 2

formation of a solid electrolyte interface (SEI) film

Methodology Applied

Scientific EffectSolid electrolyte interface formation: Electrolysis

Implementation Method 3

an electrolytic solution including a lithium salt

Methodology Applied

Scientific EffectIonic conduction: Conduction (electrical)

Data Source

PatentUS20260005320A1battery

Publication Date: 2026.01.01 NINGDE AMPEREX TECHNOLOGY LTD

AI summary

A battery includes an electrode assembly, an electrolytic solution, a package accommodating the electrode assembly, a first tab, a second tab, and a first filler. The electrode assembly is formed by winding a first electrode plate and a second electrode plate stacked. The first current collector includes a first blank region, a first single-surface-coated region, and a first double-surface-coated region. The first blank region includes a first planar region and a first bent region. The first single-surface-coated region includes a second bent region and a second planar region. The first tab is disposed in the first planar region. The second tab is disposed on the second electrode plate. The first filler is disposed in the first planar region or the second planar region. Projections of the first filler, the first tab, and the second tab in a thickness direction of the electrode assembly do not overlap.