Curved Expanded-Metal Battery Electrode for Dense Filling
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Solution Overview
Problem
Non-aqueous electrolyte batteries face issues with the deformation and breakage of expanded metal electrodes during the filling and rolling process, leading to deteriorated current collecting properties and battery performance due to excessive stress.
Innovation Solution
The use of expanded metal with a frame portion comprising strands that have a bent or curved shape, providing extensibility and preventing excessive deformation, along with specific dimensions and materials for the metal plate and positive electrode active material, ensures high energy density and discharge performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the expanded metal is filled and rolled with a mixture containing active material and binder, then the electrode is formed with good current collecting property, but the frame portion of the expanded metal deforms and breaks due to excessive stress
Solution Approach 1:
The patent applies curvature to the strands of the expanded metal by introducing bent portions with a curvature radius of 0.1mm to 5mm. This curvature allows the strands to flex and absorb stress during the filling and rolling process, preventing breakage while maintaining the structural integrity needed for current collection. The curved geometry acts as a stress-relief mechanism that preserves both strength and electrical conductivity.
2Quantity of substance
If the mixture is densely filled to increase energy density, then the battery energy density improves, but the frame portion of the expanded metal breaks due to increased stress
Solution Approach 1:
The bent portions with specific curvature radius (0.1mm to 5mm) enable the expanded metal to accommodate dense filling of active material without breaking. The curvature provides flexibility that allows the structure to deform elastically under the increased stress of dense packing, then recover, maintaining both high energy density and structural integrity.
3Ease of manufacture
If straight strands are used in the expanded metal, then the manufacturing is simpler, but the frame portion breaks easily during filling and rolling
Solution Approach 1:
While straight strands would be simpler to manufacture, the patent introduces controlled curvature with a specific radius (0.1mm to 5mm) that balances manufacturability with performance. This moderate curvature can be achieved through standard metal forming processes and provides the necessary flexibility to prevent breakage during electrode assembly, maintaining both ease of manufacture and reliability.
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
This configuration enhances the battery's energy density and discharge performance by preventing breakage and maintaining current collecting efficiency, even with dense filling, while allowing for uniform battery reactions and reduced electrical resistance.
Implementation Method 1
At least one of the plural strands surrounding the aperture has a bent shape or a curved line shape
Data Source
AI summary
A non-aqueous electrolyte battery includes a positive electrode, a negative electrode, a separator between the positive electrode and the negative electrode, and a non-aqueous electrolyte. The positive electrode includes a positive electrode active material and an expanded metal. The expanded metal includes a frame portion constituting meshes. The frame portion includes strands and bonds connecting the strands to one another. The frame portion includes strands and bonds connecting the strands to one another. Each group of plural strands out of the strands surround an aperture of a corresponding one of the meshes. The number of the plural strands surrounding the aperture is four or more. At least one of the plural strands surrounding the aperture has a bent shape or a curved line shape.