Cable-Type Battery Shape Adaptation via Segmented Electrodes
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Solution Overview
Problem
Conventional secondary batteries with plate-shaped electrodes are inflexible and prone to structural issues, making them unsuitable for devices with unique spaces and limiting their use in innovative designs, as they cannot be easily bent or twisted to fit specific applications.
Innovation Solution
A cable-type secondary battery with a novel linear structure featuring a first polarity current collector with asymmetrical cross-section, spaced active material layers, an electrolyte layer, and a second polarity current collector that can be continuously bent into an 'S' shape, enhancing flexibility and stability by utilizing a cover member to protect the electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional plate-shaped electrode structure is used, then high degree of integration is achieved during winding or stacking, but the battery cannot freely change in shape and is limited in use
Solution Approach 1:
The electrode assembly is divided into multiple unit electrodes (anode/separator/cathode stacks) that are sequentially connected in series. Each unit electrode can be independently formed and then connected to others, allowing modular assembly that adapts to various shapes while maintaining structural integrity
Solution Approach 2:
The patent transitions from traditional 2D plate-shaped electrodes to a 3D cable-type structure where unit electrodes are connected in series along a longitudinal axis. This dimensional transformation enables the battery to bend and twist in three-dimensional space while maintaining electrical connectivity through the series-connected structure
2Adaptability or versatility
If a cable-type secondary battery structure is used, then flexibility is improved, but the active materials may separate when excessively deformed
Solution Approach 1:
The battery structure incorporates predetermined bendable regions with increased spacing between unit electrodes, creating buffer zones that absorb deformation stress before it reaches the active materials. This preemptive design protects the active materials from separation during excessive deformation
Solution Approach 2:
The patent employs flexible current collectors and protective coatings that maintain structural integrity during bending. The current collectors are designed with appropriate thickness and material properties to flex without breaking, while protective films prevent active material detachment during deformation
3Reliability
If plate-shaped electrodes are used, then structural stability is maintained, but gas generated in the cells is not easily discharged
Solution Approach 1:
The cable-type battery structure with its curved, three-dimensional configuration provides natural pathways for gas to escape along the bends and curves of the cable, unlike rigid plate structures where gas becomes trapped. The curved geometry facilitates gas movement toward discharge points
Data Source
Figure 1~2
AI summary
A method for manufacturing a cable-type secondary battery includes: preparing a first polarity current collector having a long and thin shape; forming at least two first polarity electrode active material layers on the first polarity current collector to be spaced apart from each other in the longitudinal direction; forming an electrolyte layer to surround at least two first polarity electrode active material layers; forming at least two second polarity electrode active material layers on the electrolyte layer to be spaced apart from each other at positions corresponding to the first polarity electrode active material layers; forming an electrode assembly by surrounding the second polarity electrode active material layers with a second polarity current collector; surrounding the electrode assembly with a cover member; and bending the electrode assembly and the cover member into a substantially "S" shape with respect to a space between the first polarity electrode active material layers.