Battery Electrode Sheet Layout for Lower Resistance and Higher Energy Density
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Solution Overview
Problem
Existing battery electrode sheets face challenges in reducing internal resistance and improving energy density, leading to inefficiencies in charge and discharge performance and increased failure probabilities due to single-point failures in electrode tabs and uniform active material coating methods.
Innovation Solution
The proposed electrode sheet features a current collector with parallel electrode tabs that protrude beyond its edge, allowing for reduced internal resistance and enhanced discharge performance, along with a unique coating configuration where one end has flush and the other end has misaligned coated zones, improving energy density and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple electrode tabs are provided in parallel, then internal resistance is reduced and discharge performance is improved, but device complexity increases
Solution Approach 1:
The electrode sheet is divided into multiple coated zones (first coated zone and second coated zone) separated by uncoated zones, with each zone having its own electrode tabs. This segmentation allows parallel current paths through multiple tabs, reducing internal resistance while maintaining a manageable structural complexity through systematic division of the electrode body.
Solution Approach 2:
Electrode tabs are arranged not only along the length of the current collector but also distributed across different surfaces (first surface and second surface). This multi-dimensional arrangement of tabs creates additional parallel current pathways without proportionally increasing structural complexity, as tabs are integrated into the existing current collector geometry.
2Quantity of substance
If flush and misaligned coated zones are used, then energy density is improved, but manufacturing precision requirements increase
Solution Approach 1:
Different regions of the current collector are assigned different coating configurations: the first coated zone is positioned to be flush with the second coated zone at one end, while at the other end they are misaligned to create single-sided coated zones. This local differentiation optimizes energy density in specific regions without requiring uniform high-precision alignment across the entire electrode, as each zone has its own alignment characteristics suited to its function.
Solution Approach 2:
The electrode sheet is divided into multiple coated zones separated by uncoated zones, allowing independent positioning and alignment of each coated zone. This segmentation enables the flush and misaligned configurations to be implemented with controlled precision requirements for each zone rather than requiring high precision across the entire electrode structure.
3Productivity
If single-sided coated zones are formed, then production efficiency is improved, but coating uniformity control becomes more difficult
Solution Approach 1:
The electrode sheet is divided into multiple coated zones (first coated zone and second coated zone) separated by uncoated zones. This segmentation creates distinct coating regions that can be independently controlled, allowing single-sided coated zones to be formed in specific areas without requiring complex coordination across the entire electrode, thereby improving production efficiency while maintaining manageable coating uniformity control for each zone.
Data Source
AI summary
An electrode sheet has a first end and a second end opposite each other, and includes a current collector, active materials disposed on a first coated zone and a second coated zone, and a plurality of electrode tabs. The current collector includes a side edge, opposing first and second surfaces. The first surface includes a first coated zone and a first uncoated zone, and the second surface includes a second coated zone. At the first end, the first coated zone and the second coated zone are flush. At the second end, the first coated zone is misaligned with the second coated zone. The sum of the length of the first coated zone and the length of the first uncoated zone is equal to the length of the second coated zone. Each electrode tab is coupled to the current collector and protrudes beyond the side edge.