Battery Electrode Thickness Profile for Compression Damage Control

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Solution Overview

Problem

Existing rechargeable battery electrode manufacturing processes face challenges in minimizing damage to substrates due to differences in elongation between coated and uncoated regions during compression, leading to reduced productivity and potential electrode damage.

Innovation Solution

The electrode design features a substrate with a first pressurized region and a second pressurized region, where the active material layer has a thicker first portion and a thinner second portion, with the second portion gradually decreasing in thickness, allowing for a multi-stage structure and symmetrical or asymmetrical layering to reduce pressure differences and prevent substrate damage during compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If uniform thickness active material layer is applied during compression, then manufacturing process is simple, but substrate damage occurs due to elongation differences between coated and uncoated regions

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidsubstrate integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The active material layer is designed with non-uniform thickness, featuring a first thickness in the coated region and a second thickness (greater than the first) in the uncoated region. This local variation in thickness compensates for elongation differences during compression, preventing substrate damage while maintaining manufacturing simplicity.

Inventive Principle:

Principle #3Local quality

2Quantity of substance

If thicker active material layer is applied to increase capacity, then energy density improves, but pressure differences during compression increase causing substrate damage

Engineering Contradiction:

Improveactive material quantityVSAvoidsubstrate damage from pressure differences

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The active material layer exhibits spatially varying thickness to balance capacity and pressure distribution. The uncoated region has greater thickness to compensate for higher pressure during compression, while the coated region maintains standard thickness. This local differentiation allows increased overall capacity while preventing substrate damage.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The thicker active material layer in the uncoated region acts as a cushioning element before compression occurs. This pre-designed thickness variation absorbs and distributes compression forces, preventing substrate damage before it can occur during the battery manufacturing process.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Strength

If compression force is increased to improve contact, then electrode assembly integrity improves, but substrate damage increases due to elongation differences

Engineering Contradiction:

Improveelectrode assembly integrityVSAvoidsubstrate integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The non-uniform thickness distribution creates localized compliance zones. The thicker uncoated region provides additional compliance that absorbs compression forces, allowing higher overall compression forces to be applied for improved contact while preventing substrate damage through localized stress distribution.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250006945A1Electrode, electrode assembly and rechargeable battery including the same

Publication Date: 2025.01.02 SAMSUNG SDI CO LTD

AI summary

A rechargeable battery electrode includes a substrate including a first pressurized region and a second pressurized region, and an active material layer on the substrate, the active material layer including a first portion on the first pressurized region and a second portion on the second pressurized region, and a thickness of the first portion being thicker than a thickness of the second portion.