Electrode Assembly Radical Unit Stacking for Polymer Battery Alignment
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Solution Overview
Problem
Existing secondary battery electrode assembly structures, such as stack-type and stack/folding types, face challenges in accurate alignment and complex manufacturing processes, particularly in aligning full cells or bi-cells.
Innovation Solution
A novel electrode assembly structure featuring a cell stack part with alternately disposed electrodes and separators, forming a four-layered or repeating structure, and an auxiliary unit on the uppermost or lowermost part, allowing for simple and accurate alignment through the repeated stacking of radical units in a predetermined order.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a stack-type structure is used for electrode assembly, then the battery can be manufactured with separate stacking of electrode units, but accurate alignment of the electrode assembly becomes very difficult
Solution Approach 1:
The electrode assembly is divided into multiple electrode units, each comprising a cathode, anode, and separator stacked together. These modular units are then connected in series through connection portions, allowing independent manufacturing and assembly of each unit while maintaining overall alignment through the structured connection system.
Solution Approach 2:
Connection portions are introduced as intermediary elements between adjacent electrode units. These connection portions include connection electrodes that extend from both electrode units and are stacked together, serving as mediators that facilitate precise alignment and electrical connection between separate electrode units while compensating for alignment tolerances.
2Adaptability or versatility
If a stack/folding type structure is used for electrode assembly, then full cells or bi-cells can be stacked through folding, but the alignment of the full cells or bi-cells becomes difficult
Solution Approach 1:
The electrode assembly is segmented into discrete electrode units that can be independently manufactured and then systematically arranged. Each unit maintains its structural integrity and alignment features, allowing flexible configuration (stacking or folding) while preserving alignment through the modular design and connection portions.
Solution Approach 2:
The invention transitions from planar stacking to three-dimensional arrangement of electrode units. Connection portions extend in multiple directions and layers, enabling electrode units to be connected not only in series but also in parallel configurations, thereby achieving complex cell architectures (full cells, bi-cells) with maintained alignment through spatial distribution.
3Ease of manufacture
If a stack-type structure is used for electrode assembly, then electrode units can be separately stacked, but a large number of processes are necessary for manufacturing
Solution Approach 1:
Multiple electrode units are merged into a single integrated electrode assembly through the connection portions. The connection electrodes from adjacent units are stacked and connected together, combining multiple separate manufacturing operations into a unified structure that reduces the number of distinct manufacturing processes required.
Solution Approach 2:
The connection portions serve multiple functions simultaneously: they provide electrical connection between electrode units, maintain mechanical alignment, enable structural integrity during assembly, and facilitate both series and parallel configurations. This multi-functionality reduces the need for separate components and processes for each function.
Data Source
AI summary
An electrode assembly includes a cell stack part having (a) a structure in which one kind of radical unit is repeatedly disposed and has same number of electrodes and separators which are alternately disposed and integrally combined, or (b) a structure in which at least two kinds of radical units are disposed in a predetermined order, and an auxiliary unit disposed on at least one among an uppermost part or a lowermost part of the cell stack part. The one kind of radical unit of (a) has a four-layered structure in which a first electrode, a first separator, a second electrode and a second separator are sequentially stacked or a repeating structure in which the four-layered structure is repeatedly stacked, and each of the at least two kinds of radical units are stacked by ones in the predetermined order to form the four-layered structure or the repeating structure.