Battery Insulating Layer Flush with Electrode Active Material
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Solution Overview
Problem
Conventional battery manufacturing faces challenges in precisely controlling the area of positive-electrode and negative-electrode active material layers, leading to low volume energy density and increased manufacturing complexity, with the need for high dimensional accuracy and additional inspection steps.
Innovation Solution
A battery design featuring an electrode layer with a collector, an electrode active material layer, and an insulating layer, where the insulating layer is flush with the electrode active material layer and positioned between the collector and the electrode active material layer, reducing exposure and preventing short circuits, while allowing for easier adjustment of the insulating layer's area to minimize non-functional regions and enhance energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the area of electrode active material layers is precisely controlled, then manufacturing complexity and inspection steps increase, but volume energy density improves
Solution Approach 1:
The insulating layer acts as an intermediary element between the electrode active material layer and the collector. By positioning the insulating layer at the ends of the electrode layer, the patent eliminates the need for precise area control of the electrode active material layer itself. The insulating layer serves as a reference boundary that simplifies manufacturing tolerances while maintaining effective electrode area control.
2Quantity of substance
If the insulating layer area is reduced, then non-functional regions decrease and energy density increases, but short circuit risk may increase
Solution Approach 1:
The insulating layer is strategically positioned only at the ends of the electrode layer rather than covering the entire surface. This local application provides sufficient electrical isolation and short circuit prevention at critical areas while minimizing the non-functional region area, thereby maintaining high energy density without compromising reliability.
3Ease of manufacture
If the insulating layer is positioned flush with the electrode active material layer, then manufacturing simplicity increases, but exposure reduction effectiveness may be limited
Solution Approach 1:
The insulating layer extends beyond the electrode active material layer in the planar dimension, creating an overlapping region. This dimensional extension provides dual benefits: it maintains manufacturing simplicity through flush positioning while simultaneously increasing coverage area to better prevent exposure and short circuits at the electrode edges.
Data Source
AI summary
A battery includes an electrode layer, a counter-electrode layer placed opposite to the electrode layer, and a solid electrolyte layer located between the electrode layer and the counter-electrode layer. The electrode layer includes a collector, an electrode active material layer located between the collector and the solid electrolyte layer, and an insulating layer located between the collector and the electrode active material layer at ends of the electrode layer. The counter-electrode layer has a counter-electrode active material layer placed opposite to the electrode active material layer. The electrode active material layer has a region that does not overlap the insulating layer in plan view. A side surface of the insulating layer and a side surface of the electrode active material layer are flush with each other.