Cylindrical Battery Insulation Layer Layout for R-Corner Isolation
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Solution Overview
Problem
Existing cylindrical batteries face challenges in ensuring safety and energy density, particularly due to issues with short circuits and the need for adhesive affixing processes that increase manufacturing costs.
Innovation Solution
A cylindrical battery design featuring a jelly-roll electrode assembly with a tailored insulation layer that covers the R-corners and prevents short circuits, eliminating the need for adhesives by optimizing the width and angle of the insulation layer, allowing for efficient welding and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation layer is added to prevent short circuits and cover R-corners, then safety is improved, but device complexity and manufacturing cost increase due to additional adhesive affixing processes
Solution Approach 1:
The insulation layer is integrated with the positive electrode plate structure, combining the insulation function with the existing electrode assembly. The insulation layer is disposed on the positive current collector in a unified structure, eliminating the need for separate adhesive affixing processes and reducing manufacturing complexity while maintaining safety
Solution Approach 2:
The insulation layer serves multiple functions simultaneously: it provides electrical insulation to prevent short circuits, covers the R-corners of the electrode assembly, and integrates with the positive electrode plate structure. This multi-functionality reduces the need for additional components and processes
2Reliability
If the insulation layer width is increased to cover R-corners and prevent short circuits, then safety is improved, but manufacturing precision requirements increase
Solution Approach 1:
The insulation layer width is optimized locally at critical areas. The first width W1 is designed for the region corresponding to the positive active material layer, while the second width W2 is designed for the region corresponding to the insulation layer only. This local quality approach ensures adequate coverage at R-corners while maintaining reasonable manufacturing precision requirements
Solution Approach 2:
The patent specifies parameter ranges for the insulation layer widths (W1 and W2) rather than fixed values, allowing flexibility in manufacturing. The relationship W1+2mm≤W2≤W1+10mm provides a controlled parameter change that ensures safety while accommodating normal manufacturing variations
Data Source
AI summary
A cylindrical battery includes a jelly-roll delectrode assembly with a positive electrode plate. The positive electrode plate includes a current collector, a positive active material layer, and an insulation layer. Both the positive active material layer and the insulation layer are disposed on at least one side of the positive current collector. The positive current collector includes a first region corresponding to the positive active material layer, a second region corresponding to the insulation layer, and a third region covered by neither the positive active material layer nor the insulation layer. The second region is located between the first region and the third region in a width direction of the positive current collector. The insulation layer includes a first part possessing a first width W1 and a second part possessing a second width W2, satisfying: W1+2 mm≤W2≤W1+10 mm.