Bent Electrode Assembly Layout for Faster Battery Cell Stacking
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Solution Overview
Problem
The production efficiency of electrode assemblies in battery cells is low, leading to issues such as low stacking efficiency, increased folding times, and higher risks of cutting burrs and fractures during the bending process.
Innovation Solution
An electrode assembly design that includes a first electrode plate between two adjacent straight sections of a bent portion, with at least two second electrode plates stacked and bent to form a bent section, and the use of spacers to increase the number of electrode plates and improve adhesive force, reducing the number of folding times and cut edges while increasing the bending radius.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional electrode assembly forming methods are used, then the structure is simple, but the production efficiency is low and stacking efficiency is reduced
Solution Approach 1:
The electrode assembly is divided into multiple straight sections connected by bent sections, allowing independent formation and stacking of each segment. This segmentation enables parallel processing and improves stacking efficiency without significantly increasing overall structural complexity.
Solution Approach 2:
The electrode plates are bent into three-dimensional configurations with multiple straight sections arranged in different spatial dimensions. This dimensional transformation allows more electrode plates to be stacked within the same footprint area, improving production efficiency while maintaining manageable structural complexity.
2Quantity of substance
If the number of folding times is increased, then more electrode plates can be formed, but the production cycle is extended
Solution Approach 1:
Multiple electrode plates are combined into a single continuous structure with bent sections that create multiple straight segments. This merging allows multiple electrode plates to be formed in one continuous process rather than through multiple separate folding operations, increasing the number of electrode plates while reducing the production cycle.
3Reliability
If the number of first electrode plates is increased, then the assembly is more complete, but the number of cut edges increases leading to more burrs and powder falling
Solution Approach 1:
Instead of increasing the number of first electrode plates to achieve assembly completeness, the invention inverts the approach by using multiple second electrode plates with bent sections. This inversion maintains assembly completeness while reducing the total number of cut edges, thereby minimizing cutting burrs and powder falling.
4Ease of manufacture
If the bending radius is decreased, then the bending process is easier, but the risk of fracture and powder falling increases
Solution Approach 1:
Different sections of the electrode assembly have different structural qualities - straight sections maintain full strength while bent sections are strategically designed with adequate radii. This local quality differentiation allows easy bending in specific areas while maintaining high reliability and preventing fracture in critical regions.
Data Source
AI summary
Embodiments of the present application provides an electrode assembly and a manufacturing method thereof, a battery cell, a battery, and an electrical apparatus. The electrode assembly comprises: a first electrode plate; and at least two second electrode plates stacked and bent to form at least one bent portion, the bent portion comprising at least one bent section and at least two straight sections, two adjacent straight sections being connected through the bent section, where for each bent portion, the first electrode plate is provided between two adjacent straight sections, and the polarity of the first electrode plate is opposite to the polarity of the adjacent second electrode plate.