Electrode Assembly Step Portion Stabilization via Tape
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Solution Overview
Problem
Existing electrode assemblies with irregular structures, such as those with steps, face challenges in maintaining their shape and stacking form due to differences in electrode size and shape, leading to instability and potential defects during device integration.
Innovation Solution
An electrode assembly with a step portion is designed by stacking electrode laminates of different areas, where the first electrode laminate and second electrode laminate are oriented perpendicular to each other, and tape is applied to the sides to create a stepped shape, ensuring stability and adhesion, using a probe with a tape guide and roller to maintain the correct shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrodes of different sizes and shapes are stacked to form irregular battery structures with steps, then battery design flexibility and adaptability are improved, but the stability of the electrode assembly shape and stacking form deteriorates
Solution Approach 1:
The patent applies tape (a thin film material) to wrap around the electrode assembly at the step portion, creating a flexible constraint system that adapts to the irregular geometry while maintaining stacking stability. The tape conforms to the stepped shape and provides continuous support across the transition zone between different electrode levels.
Solution Approach 2:
The tape acts as an intermediary element between the stacked electrodes of different sizes, providing a bridging mechanism that maintains positional relationships and prevents misalignment. This mediator component enables the irregular structure to maintain stability without requiring rigid constraints.
2Stability of the object's composition
If tape is applied to maintain the shape of irregular battery structures, then stacking form stability is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The tape is applied in advance during the assembly process to prevent shape instability before it occurs. By pre-constraining the electrode laminates at the step portion, the manufacturing process avoids subsequent alignment issues and rework, simplifying the overall production workflow despite the additional taping step.
3Ease of manufacture
If standard batteries with uniform electrode sizes are used, then manufacturing simplicity is maintained, but adaptability to miniaturized devices and irregular structures decreases
Solution Approach 1:
The electrode assembly is segmented into multiple electrode laminates with different footprints, allowing the battery to be divided into functional zones that adapt to irregular device spaces. This segmentation enables customization for miniaturized devices while using standardized manufacturing processes for each segment.
Solution Approach 2:
The patent deliberately introduces asymmetry in the electrode laminate sizes and shapes to create irregular battery structures that fit miniaturized devices. The asymmetric design allows optimization of space utilization and electrical performance for specific device form factors while maintaining manufacturability through modular assembly.
Data Source
AI summary
An electrode assembly and a method of manufacturing the same are provided. The electrode assembly includes a first electrode laminate formed by stacking one or more electrode units having a first area, and a second electrode laminate formed by stacking one or more electrode units having a second area different from the first area. The first electrode laminate and the second electrode laminate are stacked on each other in a direction perpendicular to a plane and have a step portion formed by a difference in areas of the first and second electrode laminates, the step portion is present on at least one side of four sides of the electrode assembly, at least one step portion includes at least a portion of tape taped across a stacked side, and the portion of tape has a form corresponding to a stepped shape of the step portion.