Curved Electrode Assembly with Thermoplastic Separator
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Solution Overview
Problem
Conventional lithium batteries with flat surface geometry inefficiently use inner space and lack the flexibility to be applied in devices with various shapes or sizes, and the adhesion between the separator and electrode plate is not strong enough to achieve high strength.
Innovation Solution
A curved electrode assembly is developed with a thermoplastic polymer-coated separator between the electrodes, allowing efficient use of inner space and improved adhesion, which is then accommodated in a case and curved to the center of an axis parallel to its edge, enhancing the battery's capacity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat surface geometry is used for lithium batteries, then the manufacturing process is simple, but the inner space cannot be used efficiently and the battery cannot be applied to devices with various shapes
Solution Approach 1:
The electrode assembly is designed with a curved surface geometry instead of a flat shape. The battery can be curved to match the contours of electronic devices, improving space utilization and adaptability to various device shapes while maintaining manufacturing feasibility through the coating process
2Device complexity
If the separator is made without coated layer to simplify structure, then the manufacturing is easier, but the adhesion between separator and electrode plate is insufficient
Solution Approach 1:
The separator is constructed as a composite material with a base separator layer and an additional coated layer comprising thermoplastic polymer, inorganic particles, and binder. This composite structure enhances adhesion between the separator and electrode plate while maintaining reasonable manufacturing complexity
3Volume of moving object
If a curved electrode assembly is implemented to improve space utilization, then the battery capacity increases, but the manufacturing process becomes more complex
Solution Approach 1:
The electrode assembly is designed with a curved surface geometry instead of a flat shape. The battery can be curved to match the contours of electronic devices, improving space utilization and adaptability to various device shapes while maintaining manufacturing feasibility through the coating process
Solution Approach 2:
The coated layer on the separator undergoes phase transition during heating, changing from a non-adherent state to an adherent state that bonds with the electrode plate. This parameter change (temperature-induced phase transition) enables strong adhesion without complex manufacturing processes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The curved battery design efficiently utilizes space and improves adhesion between the separator and electrodes, resulting in a high-capacity battery that can be easily applied to devices with streamlined shapes while maintaining structural integrity.
Implementation Method 1
the separator has a coated layer of a thermoplastic polymer on at least one side thereof
Implementation Method 2
improved adhesion between a separator and an electrode plate
Data Source
AI summary
An electrode assembly is prepared by stacking and winding a first electrode, a second electrode, and a separator disposed between the first and second electrodes. The electrode assembly is curved to the center of an axis that is substantially parallel to a length direction of the electrode assembly, and the separator has a coated layer of a thermoplastic polymer on at least one side thereof. A battery cell including the electrode assembly, and a method of preparing the battery cell have also been disclosed. The battery cell including the electrode assembly may have a high strength.