Composite Pole Piece Layout for Battery Cell Alignment Control
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Solution Overview
Problem
Existing battery cell manufacturing processes face challenges in achieving precise alignment of electrode and separator components during high-speed production, leading to misalignment and safety hazards due to potential conductive contact between positive and negative electrodes.
Innovation Solution
A composite electrode sheet design featuring an insulating layer with positive and negative electrode conductor layers, where the conductor layers' widths are defined by the insulating layer's width, and reserved areas for external conductors ensure accurate alignment and connection, eliminating the need for precise alignment during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional separate electrode sheets with external conductors are used, then connection flexibility is improved, but alignment precision deteriorates due to difficulty in controlling alignment during high-speed winding and stacking
Solution Approach 1:
The patent combines the electrode sheet and current collector into a single integrated composite structure. The current collector layers are directly formed on opposite sides of the insulating layer, creating a unified component that eliminates the need for separate electrode sheets and external conductors. This integration ensures that the electrodes and current collectors maintain precise relative positioning throughout the winding and stacking processes, solving the alignment precision problem while preserving connection flexibility through the built-in conductor extensions.
Solution Approach 2:
The patent performs preliminary formation of the current collector layers on the insulating layer before the winding or stacking process. The conductive layers are pre-positioned and bonded to the insulating layer, creating a pre-assembled unit with built-in alignment. This preliminary action eliminates the need for real-time alignment control during high-speed manufacturing, as the components are already precisely positioned in the composite structure.
2Reliability
If separate electrode sheets with external conductors are used, then electrical connection is improved, but safety deteriorates due to risk of conductive contact between positive and negative electrodes
Solution Approach 1:
The patent introduces an insulating layer as an intermediary barrier between the positive and negative electrode/current collector assemblies. This insulating layer physically separates the conductive components of opposite polarity, preventing direct conductive contact while allowing the structure to function as a unified composite. The insulating layer acts as a mediator that enables electrical connection through designated pathways while blocking harmful direct contact between electrodes.
3Manufacturing precision
If precise alignment is required during assembly, then alignment accuracy is improved, but manufacturing complexity increases due to difficulty in controlling alignment during high-speed production
Solution Approach 1:
By merging the electrode sheets and current collectors into a single composite structure with the insulating layer, the patent eliminates the need for separate alignment operations during assembly. The components are inherently aligned through their integrated formation, simplifying the manufacturing process while maintaining high alignment accuracy. The composite structure reduces the number of discrete parts that need to be aligned, thereby reducing overall manufacturing complexity.
Data Source
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AI summary
The present invention relates to the technical field of batteries, in particular to composite pole pieces and a preparation method therefor, and battery cells and a preparation method therefor. The composite pole piece comprises a composite current collector, a positive electrode material layer, and a negative electrode material layer. The composite current collector comprises an insulating layer, a positive electrode conductor layer, and a negative electrode conductor layer; a first surface of the insulating layer is provided with the positive electrode conductor layer, and a second surface of the insulating layer is provided with the negative electrode conductor layer; the positive electrode material layer is arranged on a surface, away from the insulating layer, of the positive electrode conductor layer; the negative electrode material layer is arranged on a surface, away from the insulating layer, of the negative electrode conductor layer; the width of the insulating layer ≥ the width of the positive electrode conductor layer ≥ the width of the positive electrode material layer; and the width of the insulating layer ≥ the width of the negative electrode conductor layer ≥ the width of the negative electrode material layer. The composite pole piece of the present invention can solve the problem that an alignment degree is difficult to control in high-speed preparation of battery cells, and thereby improves manufacturing speed and optimal rate, so that it can be guaranteed that the battery cells have high safety performance and electrochemical performance.