Rechargeable Battery Electrode Assembly Miswinding Prevention
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Solution Overview
Problem
High-capacity rechargeable batteries often experience miswinding during the winding process of their electrode assemblies, leading to alignment disturbances and reduced performance.
Innovation Solution
The rechargeable battery design includes an electrode assembly with a first electrode plate having uncoated regions for folding, a second electrode plate inserted between the first, and separators to minimize miswinding, along with electrode tabs for secure winding, ensuring proper alignment and preventing misalignment during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrodes are wound around a winding center, then the electrode assembly can be formed, but miswinding and alignment disturbance occur
Solution Approach 1:
The electrode plates are pre-formed with uncoated regions at specific positions before the winding process. These uncoated regions serve as predetermined folding locations that guide the winding process and prevent misalignment, allowing the electrodes to be wound without disturbance while maintaining high manufacturing precision
Solution Approach 2:
The electrode plates are divided into coated regions (with active material) and uncoated regions (without active material). The uncoated regions are segmented out to create folding portions that can be manipulated independently during winding, enabling precise alignment control while maintaining ease of manufacture
2Reliability
If uncoated regions are created for folding, then miswinding is prevented, but electrode plate complexity increases
Solution Approach 1:
The uncoated regions serve multiple functions: they act as folding portions for alignment, provide bonding areas for connecting electrode tabs, and maintain structural integrity during winding. This multi-functionality prevents miswinding without requiring additional separate components, thereby avoiding increased device complexity
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
This design effectively prevents miswinding and ensures proper alignment of the electrode assembly, enhancing the battery's performance and reliability by maintaining the structural integrity during the winding process.
Implementation Method 1
a first uncoated region positioned between the first and second coated regions and not formed with the active material layer and folded at the first uncoated region
Implementation Method 2
the first separator may be folded together with the first electrode plate to enclose the second electrode plate
Implementation Method 3
a first electrode tab bonded to the first uncoated region
Data Source
AI summary
A rechargeable battery according to an exemplary embodiment of the present invention includes an electrode assembly including: a first electrode plate including first and second coated regions where an active material layer is formed and a first uncoated region positioned between the first and second coated regions and not formed with the active material layer and folded at the first uncoated region; a second electrode plate inserted between the first electrode plate; and a first separator inserted between the first and second electrode plates, and a first electrode tab bonded to the first uncoated region, wherein the first electrode plate, the second electrode plate, and the first separator are wound after they are stacked.