Battery Electrode Aperture Formation for Uniform Electrolyte Distribution

Solution Overview

Problem

Secondary batteries face challenges in uniform electrolyte impregnation and gas trapping due to their stacked structure, leading to performance deterioration and increased manufacturing complexity and cost.

Innovation Solution

Forming apertures through the active material coating layer and current collector during the notching process for electrode tab formation simplifies the manufacturing process, improves electrolyte impregnation, and reduces production costs by eliminating the need for separate aperture forming equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate aperture forming process is introduced to improve electrolyte impregnation, then electrolyte distribution is improved, but manufacturing process complexity and production cost increase

Engineering Contradiction:

Improveelectrolyte impregnationVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The aperture forming operation is merged with the existing notching process for electrode tab formation. The notching device is modified to include aperture forming capability, combining two functions (notching and aperture forming) into a single integrated process, thereby eliminating the need for separate aperture forming equipment and processes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The notching device is transformed into a multi-functional device that performs both notching (for tab formation) and aperture forming operations. This universal device approach allows one piece of equipment to accomplish multiple tasks that previously required separate dedicated machines.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a separate aperture forming process is introduced to improve electrolyte impregnation, then electrolyte distribution is improved, but production cost increases

Engineering Contradiction:

Improveelectrolyte impregnationVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The aperture forming operation is merged with the existing notching process for electrode tab formation. The notching device is modified to include aperture forming capability, combining two functions (notching and aperture forming) into a single integrated process, thereby eliminating the need for separate aperture forming equipment and processes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The notching device is transformed into a multi-functional device that performs both notching (for tab formation) and aperture forming operations. This universal device approach allows one piece of equipment to accomplish multiple tasks that previously required separate dedicated machines.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If gas is trapped between electrode and separator during manufacturing, then manufacturing is simpler, but battery performance and safety deteriorate

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidbattery safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Apertures are formed in the electrode plates before assembly into the battery cell. This preliminary action creates channels that prevent gas trapping during subsequent assembly operations, ensuring proper electrolyte distribution and preventing safety issues before they can occur.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The electrode structure is modified to include apertures (porous features) that allow electrolyte penetration and gas escape. These aperture structures enable the electrode to function as a porous medium that facilitates fluid flow and prevents gas entrapment during manufacturing and operation.

Inventive Principle:

Principle #31Porous 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 method enhances electrolyte distribution, prevents gas trapping, and improves battery safety and efficiency while reducing manufacturing complexity and costs.

Implementation Method 1

forming an aperture, which penetrates through an active material coating layer and the current collector, in the coated portion coated with an electrode active material

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS10804571B2Method of manufacturing battery cell comprising electrode having aperture

Publication Date: 2020.10.13 LG ENERGY SOLUTION LTD

AI summary

A method of manufacturing a battery cell is provided. The battery cell has an electrode assembly with a plurality of unit cells that a cathode plate and an anode plate coupled to a separator. A separation sheet or a separator is interposed therebetween. The method includes applying an electrode active material a side of a current collector to manufacture a cathode plate and an anode plate and forming an electrode tab by notching the uncoated portion of the exterior periphery the current collector in the cathode plate and the anode plate where an electrode active material is not coated while forming an aperture. The aperture penetrates through an active material coating layer and the current collector in the coated portion. The method further includes coupling the cathode plate and the anode plate to a separator at a position to allow communication of the apertures to manufacture a unit cell.