Battery Structure with Spacer Layer and Glue Frame Protrusion
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Solution Overview
Problem
Conventional flexible lithium batteries face issues with lithium dendrite formation and inner shorts due to the mismatched horizontal areas of positive and negative active material layers, leading to potential structural deformation and electrical inefficiencies.
Innovation Solution
A battery structure featuring a first glue frame with a protruding part that covers exposed active material and current collector layers, maintaining the A/C ratio and isolating the active material layers to prevent lithium dendrite formation and structural weakness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the horizontal area of the positive active material layer is made smaller to match the negative active material layer, then lithium dendrite formation is reduced, but the battery capacity and electrical efficiency deteriorate
Solution Approach 1:
The battery structure is segmented into distinct functional zones: a first active material layer with larger horizontal area for high capacity, a spacer layer with smaller horizontal area for isolation, and a second active material layer for balanced electrochemistry. This segmentation allows each layer to perform its specialized function without compromising overall battery performance.
Solution Approach 2:
The spacer layer acts as an intermediary element between the first and second active material layers. It physically isolates the layers to prevent direct contact and lithium dendrite formation, while still allowing ionic transport through the electrolyte. The spacer layer mediates the contradiction by providing structural separation without completely blocking electrochemical function.
2Reliability
If the first active material layer area is reduced to match the second active material layer area, then A/C ratio balance is improved, but the battery capacity and energy density deteriorate
Solution Approach 1:
The battery is divided into functional segments with different area ratios: the first active material layer has a larger area optimized for capacity, while the second active material layer has a smaller area optimized for electrochemical balance. This segmentation enables independent optimization of each layer's function.
Solution Approach 2:
Different regions of the battery are given different qualities: the first active material layer region is designed for high capacity with larger area, while the second active material layer region is designed for electrochemical balance with smaller area. The spacer layer region provides structural isolation. This local differentiation resolves the contradiction between overall capacity and local A/C ratio balance.
3Manufacturing precision
If process control is used to maintain horizontal area ratios, then manufacturing precision is improved, but production complexity and cost increase
Solution Approach 1:
The spacer layer is pre-formed with a specific smaller horizontal area before the active material layers are assembled. This preliminary structuring of the spacer layer establishes the area ratio relationship in advance, eliminating the need for complex real-time process control during assembly. The geometric relationship is built into the structure itself rather than controlled through process parameters.
Data Source
AI summary
A battery having a protective isolation structure is disclosed comprising a first current collecting layer, a first active material layer, a spacer layer, a first glue frame, a second active material and a second current collecting layer. The first active material layer is disposed on the first current collecting layer. The spacer layer is disposed on the first active material layer. The area of the spacer layer is smaller than the area of the first active material layer so that a part of the first active material layer is exposed outside the spacer layer. The first glue frame is covering the top surface of the first active material layer exposed from the spacer layer and has a protrusion disposed on the surface of the spacer layer. The second active material layer is disposed on the surface of the spacer layer and the protrusion. The second current collecting layer is disposed on the second active material layer.