Secondary Battery Insulating Layer Edge Melting for Cutting Integrity
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Solution Overview
Problem
The existing methods for producing secondary batteries face issues with the detachment of insulating layers during cutting, leading to the loss of resin particles and generation of foreign substances, which can affect the battery's performance and reliability.
Innovation Solution
A secondary battery design that incorporates a porous insulating layer with stacked resin particles, where the resin particles are melted along the edges to create a robust bond, preventing detachment and loss during cutting, and a method involving a CO2 laser to melt the insulating layer before cutting, ensuring the resin particles are solidified before the cutting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the insulating layer is cut directly without melting, then the cutting process is simple and fast, but the insulating layer detaches and resin particles are lost
Solution Approach 1:
The insulating layer is melted along the cutting line before the actual cutting occurs. This preliminary melting action creates a bonded state that prevents resin particle loss and insulating layer detachment during subsequent cutting, while maintaining efficient production throughput
2Reliability
If the resin particles are melted to prevent detachment, then the insulating layer integrity is improved, but additional processing time and energy are required
Solution Approach 1:
The melting and cutting operations are merged into a single integrated processing step. The laser beam simultaneously melts the resin particles and performs the cutting action, eliminating the need for separate melting and cutting steps while ensuring insulating layer integrity
Solution Approach 2:
The traditional mechanical cutting system is replaced with a laser-based system that combines melting and cutting functions. The laser beam provides both the thermal energy needed to melt resin particles and the precise cutting capability, reducing device complexity compared to using separate melting and cutting apparatus
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 approach prevents the detachment of the insulating layer and loss of resin particles during cutting, enhancing the reliability and performance of the secondary battery by maintaining the integrity of the insulating layer and reducing foreign substances.
Implementation Method 1
a method involving a CO2 laser to melt the insulating layer before cutting
Implementation Method 2
the resin particles are melted along the edges to create a robust bond, preventing detachment and loss during cutting
Data Source
AI summary
A secondary battery 100 comprises a positive electrode current collector 221 and a positive electrode active material layer 223 applied on the positive electrode current collector 221 and containing at least a positive electrode active material. The lithium-ion secondary battery 100 further comprises a negative electrode current collector 241 provided so as to oppose the positive electrode current collector 221 and a negative electrode active material layer 243 applied on the negative electrode current collector 241 and containing at least a negative electrode active material. The lithium-ion secondary battery 100 is also formed with a porous insulating layer 245 which contains stacked resin particles having insulating properties and is formed so as to cover at least one of the positive electrode active material layer 223 and the negative electrode active material layer 243 (in this case, negative electrode active material layer 243). The lithium-ion secondary battery 100 further comprises, on the edge of the insulating layer 245, a molten part 246 where the resin particles are melted.