Electrode Assembly with Segmented Cell Stack for Battery Alignment

Solution Overview

Problem

Existing secondary battery cell manufacturing processes, particularly those using stack/folding type structures, face challenges in accurate alignment and complexity, leading to issues with separator overlap and adherence, which complicates the production of full cells or bi-cells.

Innovation Solution

An electrode assembly with a novel structure featuring a cell stack part formed by alternately disposing electrodes and separators in a repeating pattern, allowing for accurate alignment and simplified manufacturing, using a minimum number of separators and optimizing the size of the assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a stack/folding type structure is used, then the battery can accommodate diverse designs, but the alignment of electrode assembly becomes difficult and the manufacturing process becomes complicated

Engineering Contradiction:

Improvedesign diversityVSAvoidalignment accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The electrode assembly is divided into multiple electrode units, each comprising a cathode, separator, and anode stacked in sequence. This segmentation allows each unit to be manufactured and aligned independently, simplifying the overall assembly process while maintaining design flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from traditional planar stacking to a three-dimensional stacked configuration where electrode units are arranged vertically. This dimensional change enables better space utilization and simplifies alignment by establishing a clear hierarchical structure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If a stack/folding type structure is used, then diverse secondary batteries can be developed, but the number of manufacturing processes increases

Engineering Contradiction:

Improvebattery design varietyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The electrode assembly is divided into multiple electrode units, each comprising a cathode, separator, and anode stacked in sequence. This segmentation allows each unit to be manufactured and aligned independently, simplifying the overall assembly process while maintaining design flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stacked electrode unit structure serves as a universal building block that can be replicated and combined to create various battery configurations. This multi-functional approach allows the same basic structure to accommodate different battery designs, reducing the number of specialized manufacturing processes needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Quantity of substance

If separators are folded to form bi-cells or full cells, then cell capacity increases, but separator adherence becomes poor and alignment becomes difficult

Engineering Contradiction:

Improvecell capacityVSAvoidseparator alignment

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The electrode assembly is divided into multiple electrode units, each comprising a cathode, separator, and anode stacked in sequence. This segmentation allows each unit to be manufactured and aligned independently, simplifying the overall assembly process while maintaining design flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from traditional planar stacking to a three-dimensional stacked configuration where electrode units are arranged vertically. This dimensional change enables better space utilization and simplifies alignment by establishing a clear hierarchical structure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS10615392B2Electrode assembly and polymer secondary battery cell including the same

Publication Date: 2020.04.07 LG ENERGY SOLUTION LTD

AI summary

An electrode assembly includes a cell stack part having a structure of steps obtained by stacking at least two groups of radical units having different sizes or having different geometric shapes according to the size or the geometric shapes. The radical unit has a combined structure into one body by alternately disposing same number of electrodes and separators, and each step of the cell stack part has a structure in which one kind of radical units is disposed once or repeatedly, or a structure in which at least two kinds of radical units are disposed. The one kind of radical unit has a four-layered structure of first electrode, first separator, second electrode and second separator sequentially stacked or a repeating structure of the four-layered structure. Each of the at least two kinds of radical units are stacked by ones to form the four-layered structure or the repeating structure.