Composite Electrode Assembly for Flexible Lithium-Ion Battery
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Solution Overview
Problem
Conventional flexible lithium-ion secondary battery electrode assemblies are prone to damage and capacity reduction due to external forces like bending, and their manufacturing processes are complex and inefficient, leading to defects and reduced ion conductivity.
Innovation Solution
A composite electrode assembly is designed with a first electrode assembly, a single electrode, and a second electrode assembly stacked with a separator covering the outer surface, featuring parallel connection tabs and a pocketing structure to distribute mechanical stress and improve flexibility, while simplifying the manufacturing process by pre-welding electrode leads and using partial taping for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional flexible battery structure is used with electrode leads bent to facilitate flexibility, then flexibility is improved, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The electrode assembly is divided into multiple individual electrode plates (positive and negative) that are stacked alternately with separators. Each electrode plate can be independently manufactured and processed, allowing flexibility to be achieved through the modular structure rather than complex bending of integrated electrode leads. This segmentation enables simpler manufacturing where each unit can be processed separately before assembly.
Solution Approach 2:
Instead of achieving flexibility through three-dimensional bending of electrode leads, the patent uses a two-dimensional stacked arrangement of multiple thin electrode plates separated by flexible separators. The flexibility emerges from the layered structure's ability to compress and expand in the stacking direction, converting the flexibility problem from a lead-bending challenge into a structural arrangement solution.
2Stability of the object's composition
If electrode plates are subjected to bonding and alignment processes, then assembly is achieved, but manufacturing becomes inefficient and defects occur
Solution Approach 1:
The electrode plates and separators are designed with self-aligning features where the separators naturally position themselves between electrode plates during stacking. The structure allows automatic alignment through the alternating positive-negative electrode plate sequence, reducing the need for complex external alignment processes and bonding operations that reduce productivity and introduce defects.
3Adaptability or versatility
If external force is applied to a stacked electrode assembly, then flexibility is achieved, but the electrode plates may be damaged and capacity decreases
Solution Approach 1:
Flexible separators are placed between each electrode plate before assembly, creating protective cushioning layers that absorb and distribute external forces applied to the battery. This beforehand cushioning prevents direct force transmission to the electrode plates, protecting them from damage during bending or twisting while maintaining flexibility. The separators act as shock-absorbing elements that preserve electrode plate integrity under mechanical stress.
Data Source
AI summary
A flexible battery may include: a first electrode assembly including one or more unit cells, each having a pair of electrodes with a separator interposed therebetween; a single electrode; and a second electrode assembly connected to the first electrode assembly or to the single electrode and including a single electrode and a separator covering a top and bottom of the single electrode of the second electrode assembly.