Composite-Substrate Electrode Assembly for Lighter Secondary Batteries
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Solution Overview
Problem
Existing secondary batteries face challenges in reducing weight while maintaining safety and energy density, as thinning materials or improving active materials can compromise safety.
Innovation Solution
A secondary battery design using a composite substrate with a polymer substrate sandwiched between metal layers on both sides, and conductive fixing members like rivets to secure electrode plates and conductors, ensuring electrical connectivity without affecting active material-coated areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If materials such as substrates, separators, and outer materials are thinned to reduce weight, then weight is reduced, but safety is compromised
Solution Approach 1:
The substrate uses a composite structure combining polymer substrate with metal layers (aluminum or copper) on one or both sides. This composite material provides both the weight reduction benefits of thin polymer substrates and the safety/mechanical strength advantages of metal reinforcement, resolving the contradiction between weight reduction and safety maintenance
2Quantity of substance
If energy density is increased by improving physical properties of active materials, then energy density is improved, but safety may be reduced
Solution Approach 1:
The electrode plates use composite substrates with polymer and metal layers that enable higher energy density through optimized material properties while the metal layers provide thermal and mechanical safety management, allowing energy density improvement without sacrificing safety
3Weight of moving object
If composite substrate with polymer and metal layers is used to reduce weight, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The metal layers are pre-formed on the polymer substrate before electrode material coating, creating a ready-to-use composite substrate that simplifies subsequent manufacturing steps while achieving weight reduction and safety benefits
Data Source
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AI summary
Disclosed is a secondary battery (100) and a method (800) for manufacturing the same. The secondary battery (100) includes an electrode assembly including a plurality of electrode plates, and a plurality of conductors (320, 420, 520, 720) joined to the electrode assembly, in which each of the plurality of electrode plates includes a portion with an active material (220) on both sides of a composite substrate (210), and a non-coated portion (310, 410, 510, 710) free of the active material (220), and where one end of each of the plurality of conductors (320, 420, 520, 720) is arranged between two adjacent non-coated portions (310, 410, 510, 710) of the plurality of electrode plates.