Electrochemical Cell Electrode Isolation Frame
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Solution Overview
Problem
Conventional electrochemical cells with single electrode pairs in stacked configurations lack sufficient isolation between electrodes, leading to potential electrical shorts due to electrode deformation, debris, or metal flakes, which can cause leakage and reduce cell reliability.
Innovation Solution
Integration of a thin, electrically insulating film frame within the sealing material layer that extends beyond the electrode perimeter, providing additional isolation and preventing electrical shorts by increasing the distance electrodes must deform before shorting, and incorporating reinforcing elements and thermal conductivity for enhanced stability and monitoring capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If only a sealing material layer is used to isolate electrodes, then the cell structure remains simple, but electrical shorts may occur due to electrode deformation, debris, or metal flakes
Solution Approach 1:
The isolation function is segmented between the sealing material layer and the electrically insulating frame. The frame provides primary structural isolation while the sealing material provides secondary protection, dividing the isolation task into multiple components to enhance reliability without overwhelming complexity
Solution Approach 2:
The electrically insulating frame acts as an intermediary element between the electrodes, providing an additional barrier that prevents direct contact. This mediator component enhances electrical isolation reliability by introducing an extra layer of protection against deformation, debris, and metal flakes
2Reliability
If the adhesive layer extends only to the perimeter of the electrodes, then the manufacturing process remains simple, but it cannot defend against electrode creep and deformation
Solution Approach 1:
The frame extends beyond the electrode perimeter in the lateral dimension, creating an outwardly extending portion that provides additional isolation coverage. This dimensional extension prevents electrode creep and deformation without significantly complicating the manufacturing process
Solution Approach 2:
The frame structure is pre-formed with reinforcing elements and integrated into the sealing material layer before final assembly. This preliminary preparation ensures electrode stability is built-in from the start, reducing the need for additional manufacturing steps
3Reliability
If a thin electrically insulating film frame is integrated into the sealing material layer extending beyond electrode perimeter, then additional isolation and protection against shorts is provided, but the cell structure becomes more complex
Solution Approach 1:
The electrically insulating frame is merged with the sealing material layer to form an integrated structure. This combination provides both electrical isolation and sealing functions through a single integrated component, reducing the number of separate parts and simplifying assembly while enhancing 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
The solution effectively prevents electrical shorts and enhances cell reliability by increasing the isolation between electrodes, while also allowing for efficient heat transfer and improved handling and monitoring of the cells.
Implementation Method 1
a thin, electrically insulating film frame is embedded into the sealing material layer such that it extends out beyond the perimeter of the electrodes
Implementation Method 2
A sealing material layer 40 such as a hot melt sealant or pressure sensitive adhesive is disposed along the perimeter 23, 27 of the positive and negative electrodes
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A single electrode pair electrochemical cell (20) includes an anode foil substrate (26) having a first active material (28) pasted on an inward facing side, a cathode foil substrate (22) having a second active material (24) pasted on an inward facing side, a separator sheet (30) disposed between the anode and the cathode, a sealing material (40) such as a hot melt sealant or pressure sensitive adhesive that is disposed along the perimeter of the foils (22, 26), and an electrolyte sealed between the substrates by the sealing material. In addition, a thin plastic film frame (60) is embedded into the sealing material (40) such that it extends out beyond the perimeter of the substrates.