Broken-Seam Electrode Assembly for Low-Waste Battery Stacking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high manufacturing cost of batteries is primarily due to material waste in the stacking process of electrode assemblies, where continuous electrode sheets are broken before reaching the required number of layers, leading to scrapped materials.
Innovation Solution
An electrode assembly design featuring a first electrode sheet with a broken seam, allowing it to be folded into bending and stacking segments, which cooperate with second electrode sheets to meet layer requirements, reducing waste and cost, while diaphragms ensure alignment and connection of broken parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a continuous electrode sheet is used in the stacking process, then the structural integrity is maintained, but material waste increases when the sheet breaks before reaching the required number of layers
Solution Approach 1:
The electrode sheet is divided into multiple segments with broken seams at predetermined positions. Each segment can be independently stacked to form a complete electrode assembly, allowing partial segments to be reused rather than discarding the entire sheet when a break occurs. This segmentation enables flexible combination of broken and intact portions to achieve the required layer count.
Solution Approach 2:
Instead of discarding electrode sheet portions that break during stacking, the invention recovers and reuses these broken segments by combining them with other segments. The broken seams create modular units that can be reconfigured to form complete assemblies, transforming what would be waste material into usable components.
2Ease of manufacture
If the electrode sheet is broken into segments, then material utilization improves, but the alignment and connection difficulty increases
Solution Approach 1:
The broken seams are created at predetermined positions before the stacking process begins. This preliminary segmentation establishes fixed reference points and standardized segment dimensions, making subsequent alignment and connection operations more precise and manageable compared to handling random breaks.
Solution Approach 2:
The broken seam structure acts as an intermediary element that facilitates connection between segments. The specific structure at the broken seam positions provides a standardized interface for joining segments together, improving alignment precision through consistent geometric features.
Data Source
AI summary
Provided are an electrode assembly, a battery cell, a battery and an electrical device, belonging to the technical field of battery manufacturing. The electrode assembly comprises: a first electrode sheet, comprising a plurality of bending segments and a plurality of stacking segments arranged in layers, wherein each bending segment is configured to connect two adjacent stacking segments, the first electrode sheet has a first broken seam, and the first broken seam extends in the width direction of the first electrode sheet to break the first electrode sheet; and a plurality of second electrode sheets, wherein the polarity of the second electrode sheet is opposite to the polarity of the first electrode sheet, and each second electrode sheet is arranged between two adjacent stacking segments in the stacking direction of the plurality of stacking segments.