Co-Coated Separator Electrode Assembly for Fixed Anode-Cathode Alignment

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Solution Overview

Problem

Current secondary battery manufacturing processes require thick current collector foils to withstand active material application, leading to increased weight and volume, potential damage from metallic particles, and misalignment risks causing short circuits and thermal issues.

Innovation Solution

Coat cathodically active material on one side and anodically active material on the other side of a separator web, cut into wave pair segments for interleaving with current collectors, ensuring aligned electrode assembly without thick foils.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If thick current collector foils are used to withstand active material application, then the structural strength is improved, but the weight and volume of inactive materials increase, decreasing energy density

Engineering Contradiction:

Improvestructural strengthVSAvoidweight of inactive materials

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The invention divides the electrode structure into segments where the separator web is coated with active materials on both sides. This segmentation allows the separator to serve multiple functions (mechanical support and active electrode) eliminating the need for thick current collectors while maintaining structural integrity during processing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator web is given multiple functions: it serves as the mechanical support structure, the substrate for active material coating, and the electrode itself. This multi-functionality eliminates the need for separate thick current collector foils, reducing inactive material weight while maintaining structural strength

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If dicing is performed to generate electrode units, then the electrode assembly is formed, but metallic particles are generated and deposited on active material, introducing high risk of damage

Engineering Contradiction:

Improveelectrode assembly formationVSAvoidmetallic particle deposition

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The invention extracts the current collector material from the electrode structure, using only the separator web as the support. This elimination of metallic current collectors removes the source of metallic particles that would be generated during dicing, preventing particle deposition on active material

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention converts the potential harm of dicing by using a non-metallic separator web instead of metallic current collectors. The separator material generates no harmful metallic particles during dicing, transforming the process from harmful to benign while still enabling electrode assembly formation

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If separate coating processes are used for anode and cathode, then active materials are applied to current collectors, but misalignment occurs leading to short circuits and battery failure

Engineering Contradiction:

Improveactive material applicationVSAvoidelectrode alignment

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention merges the anode and cathode coating processes into a single simultaneous operation on opposite sides of the separator web. This integration ensures perfect alignment of electrodes since both active materials are applied to the same reference frame (the separator) in one process, eliminating misalignment issues

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The separator web serves as an intermediary reference frame that mediates the positioning of both anode and cathode active materials. By coating both sides of the separator simultaneously, the separator ensures precise alignment of electrodes, preventing short circuits while maintaining ease of manufacture

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20250219249A1Separator co-coated with anode and cathode active materials

Publication Date: 2025.07.03 ENOVIX CORP

AI summary

Systems and methods are provided herein for generating wave pair segments for use in an electrode assembly. For example, a web of ionically permeable and electrically isolating separator material may be coated on a first side with anodically active material. The web may then be coated on a second side, opposite the first side, with cathodically active material. The web may then be cut into equally sized wave-pair segments. A web of cathode current collector material may be cut into a plurality of cathode current collectors and a web of anode current collector material may be cut into a plurality of anode current collectors. The wave-pair segments and current collectors may be interleaved to form an electrode assembly where the alignment between the anode and cathode is fixed.