Battery Current Collector Insulating Portion Folding
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Solution Overview
Problem
Conventional battery manufacturing methods fail to achieve sufficient bonding strength between components, leading to potential positional shifting or separation during manufacturing and usage, which can result in short-circuiting and reduced reliability.
Innovation Solution
A battery design featuring a first current collector with electroconductive and insulating portions, where the electrode and counter electrode layers are positioned facing each other due to folding at an insulating portion, enhancing the bonding strength and preventing positional shifts or separations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional battery manufacturing methods are used to assemble components, then the manufacturing process is simple, but the bonding strength between components is insufficient leading to positional shifting or separation
Solution Approach 1:
The current collector is divided into multiple functional portions: electroconductive portions for electrical connection and an insulating portion for structural support and positioning. This segmentation allows each part to perform its specific function optimally, with the insulating portion providing bonding strength and the electroconductive portions providing electrical connectivity.
Solution Approach 2:
Different portions of the current collector have different material properties tailored to local requirements. The insulating portion is made of material with high bonding strength and electrical insulation properties, while the electroconductive portions are made of highly conductive material. This local differentiation resolves the contradiction by providing both structural integrity and electrical functionality.
2Ease of manufacture
If components are loosely assembled to ease manufacturing, then the manufacturing process is easier, but positional shifting or separation occurs during usage
Solution Approach 1:
The insulating portion of the current collector is pre-formed with specific geometric features that automatically position the electrode and counter electrode layers in the correct locations during assembly. This preliminary positioning action ensures proper component alignment is achieved easily during manufacturing, while the same structural features maintain reliable positioning during battery usage.
3Strength
If sufficient bonding strength is achieved through strong adhesives or mechanical fastening, then component bonding is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The insulating portion of the current collector serves dual functions: it provides electrical insulation and simultaneously acts as the bonding structure that holds the electrode and counter electrode layers together. This self-service approach eliminates the need for separate adhesives or mechanical fastening components, achieving strong bonding while simplifying the manufacturing process.
Data Source
AI summary
A battery includes a first current collector, a first electrode layer, and a first counter electrode layer. The first counter electrode layer is a counter electrode of the first electrode layer, and the first current collector includes a first electroconductive portion, a second electroconductive portion, and a first insulating portion. The first electrode layer is disposed in contact with the first electroconductive portion, and the first counter electrode layer is disposed in contact with the second electroconductive portion. The first insulating portion links the first electroconductive portion and the second electroconductive portion, and the first current collector is folded at the first insulating portion, whereby the first electrode layer and the first counter electrode layer are positioned facing each other.