Electrode Assembly Coating Layout for Uniform Battery Deterioration
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Solution Overview
Problem
Existing rechargeable batteries experience non-uniform deterioration due to differences in current amounts between double-sided and single-sided coated regions in the electrode plate, leading to reduced cycle-life.
Innovation Solution
The solution involves increasing the resistance of the single-sided coated region by varying the loading level, applying a binder layer, omitting a carbon-coating layer, or adjusting the orientation of the coating, thereby minimizing current amount differences and promoting uniform deterioration across the electrode plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the active material is coated in the same manner on both double-sided and single-sided coated regions, then the manufacturing process is simple, but resistance is reduced in the single-sided coated region causing current amount difference and non-uniform deterioration
Solution Approach 1:
The patent applies different coating methods to different regions of the electrode plate. The double-sided coated region uses a first coating method while the single-sided coated region uses a second coating method, creating local quality differences that equalize resistance across regions and prevent non-uniform deterioration
Solution Approach 2:
The patent changes coating parameters (such as coating amount, coating speed, or coating conditions) between the double-sided and single-sided coated regions. By adjusting these parameters, the resistance of the single-sided coated region is increased to match the double-sided region, resolving the current amount difference issue
2Reliability
If the loading level of active material is increased in the single-sided coated region, then resistance is increased to minimize current amount difference, but the coating process becomes more complex
Solution Approach 1:
The patent implements local quality by applying a higher loading level of active material specifically to the single-sided coated region compared to the double-sided coated region. This localized adjustment increases resistance in the single-sided region without complicating the overall manufacturing process
Solution Approach 2:
The patent applies excessive action by coating more active material than necessary in the single-sided coated region. This partial over-coating ensures sufficient resistance increase to balance current distribution, while the excess material does not harm the electrode performance
Data Source
AI summary
An electrode assembly, including an electrode plate at opposite sides of a separator, the electrode plate including a double-sided coated region having an active material on opposite sides of a substrate forming a current collector, and a single-sided coated region having an active material on a single surface of the substrate, wherein the single-sided coated region has a resistance that is higher than a resistance of the double-sided coated region.