Electrode Assembly Cutout Layout for Cylindrical Battery Compaction
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Solution Overview
Problem
In cylindrical rechargeable batteries, the electrode uncoated portions, which are wound into a cylindrical shape, find it difficult to be folded toward the center of the electrode assembly due to differences in radii of curvature, making the compaction process challenging.
Innovation Solution
The electrode assembly incorporates inclined cutout portions in the electrode uncoated portions, which allows for easier folding and compaction, even when the radii of curvature differ. The intervals between these cutout portions increase from the frontal end to the rear end, and the inclination angles also vary accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electrode uncoated portion is continuously wound into a cylindrical shape, then the electrode assembly can be formed, but it becomes difficult to fold the uncoated portion toward the center due to different radii of curvature
Solution Approach 1:
The electrode uncoated portion is divided into multiple segments by forming cutout portions at regular intervals. This segmentation allows each segment to be independently folded toward the center, overcoming the difficulty caused by the continuous cylindrical shape and different radii of curvature.
Solution Approach 2:
The cutout portions are strategically positioned at different locations along the electrode uncoated portion, creating local variations in structure. This allows different regions to have different folding characteristics, enabling successful compaction despite the overall cylindrical shape with varying radii of curvature.
2Reliability
If the electrode uncoated portion is folded toward the center, then electrical connection can be achieved, but the process becomes difficult when radii of curvature differ
Solution Approach 1:
By dividing the electrode uncoated portion into segments through cutout portions, the folding operation becomes simpler and more reliable. Each segment can be folded independently toward the center, ensuring consistent electrical connection without the complexity of handling the entire continuous uncoated portion.
Solution Approach 2:
The cutout portions are pre-formed in the electrode uncoated portion before the folding process. This preliminary action prepares the material for subsequent folding operations, making it easier to achieve reliable electrical connection by anticipating the folding requirements.
3Volume of moving object
If the electrode assembly is compacted, then space efficiency improves, but the compaction process becomes challenging with different radii of curvature
Solution Approach 1:
The electrode uncoated portion is segmented into multiple sections by cutout portions, which facilitates the compaction process. This segmentation allows the material to be compressed more effectively toward the center, achieving better space efficiency while simplifying the manufacturing process despite varying radii of curvature.
Solution Approach 2:
The strategic placement of cutout portions creates local structural variations that enable more effective compaction. Different regions of the electrode uncoated portion can be compressed according to their specific geometric characteristics, improving overall volume efficiency while making the compaction process more manageable.
Data Source
AI summary
An electrode assembly includes: first and second electrodes, each comprising a conductive substrate and having an electrode active portion and a first electrode uncoated portion; and a separator. The first electrode, the separator, and the second electrode are stacked on each other and wound. At least one of the first electrode uncoated portion and the second electrode uncoated portion has a plurality of inclined cutout portions inclined with respect to a length direction of the electrode assembly, and an interval between adjacent ones of the inclined cutout portions at a frontal end of the electrode assembly and an interval between adjacent ones of the inclined cutout portions at a rear end of the electrode assembly are different.