Divided Insulating Film Wrapping for Lithium Ion Battery Electrodes
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Solution Overview
Problem
The existing manufacturing methods for lithium ion secondary batteries require punching or perforating insulating polymer films to accommodate electrode plates, leading to waste and limitations in energy density and size variability.
Innovation Solution
A wrapping electrode assembly that uses a divided insulating polymer film with adhesive-coated members to cover the electrode plate, eliminating the need for punching and allowing for various sizes and higher energy density without material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If punching or perforating is performed on the insulating polymer film to accommodate the electrode plate, then the electrode plate can be properly positioned, but the insulating polymer film is wasted and material costs increase
Solution Approach 1:
The insulating polymer film is divided into multiple separate films (first insulating polymer film and second insulating polymer film) that are stacked together. The electrode plate is positioned between these stacked films, which are then bonded together. This segmentation eliminates the need for punching or perforating a single continuous film, thereby preventing material waste while maintaining precise electrode plate positioning.
2Strength
If the insulating polymer film is made continuous without divisions to improve structural integrity, then the film strength increases, but it cannot accommodate the electrode plate without punching or perforating
Solution Approach 1:
Multiple insulating polymer films are combined through stacking and bonding to create a composite structure. Each film remains continuous and intact (maintaining strength), while the stacked configuration creates accommodation spaces for the electrode plate. The bonding process merges the separate films into a unified structure that provides both strength and accommodation capability.
3Ease of manufacture
If existing manufacturing methods are used for cylindrical or prismatic batteries, then production experience is available, but energy density per volume drastically decreases when manufacturing slim batteries
Solution Approach 1:
The manufacturing approach changes from traditional cylindrical or prismatic battery construction to a flat battery structure using stacked insulating polymer films. This parameter change in structural configuration enables slim battery manufacturing while maintaining high energy density per volume, as the flat stacked architecture allows for more efficient space utilization of electrode materials.
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 approach reduces material costs, prevents waste, and enables the production of batteries with higher energy density and varied sizes using the same equipment, improving the efficiency and versatility of lithium ion secondary batteries.
Implementation Method 1
an insulating polymer film which is positioned between the first separator film and the second separator film at least on a portion of a circumference of the electrode plate to be bonded to the first separator film and the second separator film
Data Source
AI summary
A wrapping electrode assembly for use in a secondary battery manufactured by an electrode-stacking method includes: an electrode plate which has a coating layer of an electrode active material and a non-coated protruding portion, the electrode active material being capable of reversibly inserting and extracting lithium ions; first and second separator films which cover both surfaces of the electrode plate while exposing only the non-coated protruding portion; and an insulating polymer film which is positioned between the first separator film and the second separator film at least on a portion of a circumference of the electrode plate to be bonded to the first separator film and the second separator film, wherein the insulating polymer film is formed as being divided into at least two parts.