Composite Battery Electrode Structure for Higher Energy Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing secondary batteries face challenges in reducing weight and improving energy density while maintaining safety and stability, particularly due to the use of conventional metal substrates that require multiple electrode tabs and welding, which can lead to inefficiencies and increased manufacturing costs.
Innovation Solution
The use of a composite substrate with insulating layers between conductive metal materials for electrodes, allowing for reduced metal usage and optimized tab welding, along with segmented uncoated portions for improved electrical connection and reduced thickness, enhancing energy density and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional metal substrates are used for electrodes, then electrical conductivity is maintained, but weight increases and energy density decreases
Solution Approach 1:
The electrode substrate is divided into multiple layers: a base metal substrate layer and an insulating layer with uncoated portions. This segmentation allows selective metal usage only where electrical conductivity is needed, reducing overall metal quantity while maintaining functionality
Solution Approach 2:
The electrode uses a composite structure combining metal substrate layers with insulating layers. This composite material approach reduces metal content while maintaining electrical conductivity through the metal portions and providing insulation where required, thereby reducing weight and improving energy density
2Reliability
If multiple electrode tabs are used for electrical connection, then electrical connection is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
Multiple electrode tabs are merged into a single integrated tab structure. The insulating layer with uncoated portions allows multiple connection points to be combined into one unified tab assembly, reducing the number of separate welding operations while maintaining reliable electrical connection
Solution Approach 2:
The single electrode tab structure serves multiple functions: it provides electrical connection for both positive and negative electrodes, acts as a structural support element, and eliminates the need for separate welding operations for multiple tabs, thereby simplifying manufacturing
3Strength
If thicker substrates are used for structural stability, then mechanical strength is improved, but energy density decreases
Solution Approach 1:
The substrate structure implements local quality by providing full metal substrate thickness only where structural support is needed, while using thinner or insulating layers in areas where electrical conductivity or active material placement is required. This optimized thickness distribution maintains strength while maximizing active material volume
Data Source
AI summary
An electrode for a secondary battery includes a composite substrate including a first substrate and a second substrate, each of the first substrate and the second substrate including a conductive metal material, and an insulating layer between the first substrate and the second substrate, a first active material layer on the first substrate of the composite substrate, a second active material layer on the second substrate of the composite substrate, a first electrode tab coupled to the first substrate of the composite substrate, and a second electrode tab coupled to the second substrate of the composite substrate.