Electrochemical Device Current Collector Buffer Zone Design

Solution Overview

Problem

Electrochemical devices face issues such as wrinkles and fractures in current collectors during calendering and mechanical abuse, leading to reduced reliability and service life.

Innovation Solution

The electrochemical device design includes specific distance configurations between opening edges of the current collector to minimize tearing and damage, with overlapping regions and recesses to provide buffering, and uniform thickness to enhance mechanical stability and connection strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the conductive plate is connected to the current collector with a small distance between opening edges, then the connection strength is improved, but the current collector is more prone to wrinkles and damage during calendering

Engineering Contradiction:

Improveconnection strengthVSAvoidwrinkles and damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a buffer zone (distance between opening edges) before the conductive plate connects to the current collector. This buffer zone absorbs mechanical stress during calendering and device assembly, preventing direct transmission of force that would cause wrinkles or damage to the current collector, while still maintaining adequate connection strength through the conductive material layer.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Object-affected harmful factors

If the distance between opening edges is increased to prevent wrinkles, then the current collector is protected from damage, but the connection strength between conductive plate and current collector is reduced

Engineering Contradiction:

Improvewrinkles and damageVSAvoidconnection strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent optimizes the distance parameter between opening edges to fall within a specific range (0.2mm to 4mm). This parameter optimization balances two opposing requirements: providing sufficient buffer space to prevent wrinkles and damage during calendering, while maintaining adequate connection strength for reliable electrical contact between the conductive plate and current collector.

Inventive Principle:

Principle #35Parameter changes

3Volume of moving object

If the opening edges are aligned closely for compact design, then the device size is reduced, but the current collector suffers from sudden thickness changes causing tearing

Engineering Contradiction:

Improvedevice sizeVSAvoidresistance to tearing

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The patent introduces a buffer zone (distance between opening edges) before the conductive plate connects to the current collector. This buffer zone absorbs mechanical stress during calendering and device assembly, preventing direct transmission of force that would cause wrinkles or damage to the current collector, while still maintaining adequate connection strength through the conductive material layer.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent optimizes the distance parameter between opening edges to fall within a specific range (0.2mm to 4mm). This parameter optimization balances two opposing requirements: providing sufficient buffer space to prevent wrinkles and damage during calendering, while maintaining adequate connection strength for reliable electrical contact between the conductive plate and current collector.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4645577A1Electrochemical device and electronic device

Publication Date: 2025.11.05 NINGDE AMPEREX TECHNOLOGY LTD

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AI summary

An electrochemical device includes a housing, an electrode assembly, and a first conductive plate. The electrode assembly includes a first electrode plate. The first electrode plate includes a first current collector, a first conductive material layer provided with a first opening, and a second conductive material layer provided with a second opening. The first current collector includes a first surface and a second surface. The first surface includes a first region. The second surface includes a second region. When viewed from the first direction, the first region overlaps with the second region, and the first conductive plate is connected to the first region or the second region. The first opening includes first to third opening edges. The second opening includes fourth to sixth opening edges. A distance between the first opening edge and the fourth opening edge is a first distance. A distance between the second opening edge and the fifth opening edge is a second distance. A distance between the third opening edge and the sixth opening edge is a third distance. the electrochemical device satisfies at least one of the following conditions: 0.2 mm≤first distance; 2 mm≤second distance; or 0.2 mm≤third distance, so as to improve the reliability and extend the service life. An electronic device is further provided.