Ceramic-Coated Battery Electrode for Short-Circuit-Free Tab Welding
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Solution Overview
Problem
Secondary battery electrodes often experience short circuits due to uncoated portions, which can lead to electrical failures and hinder smooth tab welding processes.
Innovation Solution
A secondary battery electrode design where a ceramic layer is applied on uncoated portions of both positive and negative electrodes, forming a coupling portion that allows for smooth tab welding and prevents short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrode active material is applied on an electrode plate, then the electrode active material provides electrochemical function, but uncoated portions may cause short circuits inside the cell
Solution Approach 1:
The electrode plate surface is segmented into multiple coating regions: an active material coating region for electrochemical function and a ceramic coating region for insulation. This segmentation allows different materials to be applied in specific zones, preventing short circuits while maintaining electrochemical performance.
Solution Approach 2:
Different coating materials are applied to different regions of the electrode plate based on local functional requirements. The active material is applied where electrochemical reactions are needed, while ceramic material is applied in uncoated portions or specific areas requiring insulation, creating local quality variations that solve the short circuit problem.
2Reliability
If a ceramic layer is applied on uncoated portions to prevent short circuits, then short circuit prevention is improved, but the manufacturing process becomes more complex
Solution Approach 1:
Masking patterns are applied to the electrode plate before the coating process to define the active material coating region and ceramic coating region in advance. This preliminary action guides the subsequent coating steps, ensuring that materials are applied to the correct regions without requiring complex post-processing or rework.
Solution Approach 2:
A masking pattern acts as an intermediary tool that facilitates the coating process. The masking pattern temporarily covers specific regions during coating, allowing precise material deposition without direct complex control, and is removed after coating to reveal the desired patterned structure.
3Reliability
If the electrode plate is fully coated with active material, then electrochemical performance is maximized, but tab welding becomes difficult due to lack of exposed metal surface
Solution Approach 1:
The electrode plate is segmented into an active material coating region and a ceramic coating region, with the ceramic coating applied specifically on uncoated portions near the tab area. This segmentation allows the tab region to remain exposed or be covered with ceramic that can be removed, facilitating welding while the rest of the electrode maintains full active material coverage for optimal electrochemical performance.
Solution Approach 2:
The coating structure varies locally across the electrode plate: full active material coating in regions requiring electrochemical performance, and no coating or removable ceramic coating in regions requiring welding access. This local quality differentiation resolves the contradiction between maximizing electrochemical performance and enabling tab welding.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The additional ceramic layer effectively prevents short circuits and facilitates smooth tab welding, enhancing the reliability and performance of secondary battery electrodes.
Implementation Method 1
The ceramic layer may be laser-processed by the processing part
Data Source
AI summary
A secondary battery electrode and a method of manufacturing a secondary battery electrode are disclosed. A secondary battery electrode includes an electrode plate body including a first area and a second area, an active material layer on the first area, a ceramic layer on the second area, a coupling portion located in the second area, and a tab welded to the coupling portion.