Electrode Plate Edge Coating for Uniform Battery Thickness

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Solution Overview

Problem

Existing electrode plate manufacturing methods result in uneven thickness and difficulty in meeting target external specifications due to localized thickness variations, particularly in stacking-type rechargeable batteries.

Innovation Solution

The electrode plate includes a hydrophobic coating layer on the active material layer with an insulating portion at the boundary between the active material layer and the substrate, preventing the spread of an insulating solution and maintaining uniform thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If insulating solution is discharged to the boundary between active material layer and substrate, then insulating portion is formed for electrical isolation, but thickness uniformity deteriorates due to solution spread

Engineering Contradiction:

Improveelectrical isolationVSAvoidthickness uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

A hydrophobic coating layer is applied in advance to the edge portions of the active material layer before discharging the insulating solution. This preliminary coating creates a barrier that prevents the insulating solution from spreading onto regions where it would cause thickness non-uniformity, while still allowing the solution to reach the boundary for proper electrical isolation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The hydrophobic coating is selectively applied only to the edge portions of the active material layer, creating a localized property difference. This local treatment allows the insulating solution to be contained in specific areas while maintaining uniform thickness in other regions, resolving the contradiction between isolation effectiveness and thickness uniformity.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If hydrophobic coating layer is coated on entire top surface of active material layer, then insulating solution spread is prevented, but manufacturing complexity increases

Engineering Contradiction:

Improvethickness uniformityVSAvoidcoating process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Instead of coating the entire top surface, the hydrophobic coating is applied only to the edge portions of the active material layer. This localized approach maintains thickness uniformity by preventing solution spread at critical areas while simplifying the manufacturing process compared to full-surface coating.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design ensures improved stacking flatness and uniform thickness of the electrode plate, allowing the rechargeable battery to meet target specifications.

Implementation Method 1

a hydrophobic coating layer on at least an edge of the active material layer, the hydrophobic coating layer having a hydrophobic functional group

Methodology Applied

Scientific EffectHydrophobic effect: Hydrophobe

Data Source

PatentUS20250372658A1Electrode plate and method of manufacturing the same

Publication Date: 2025.12.04 SAMSUNG SDI CO LTD

AI summary

An electrode plate includes a substrate, an active material layer on the substrate, a hydrophobic coating layer on at least an edge of the active material layer, the hydrophobic coating layer having a hydrophobic functional group, and an insulating portion at a boundary between the active material layer and the substrate, the insulating portion covering at least a part of a side surface of the active material layer below the hydrophobic coating layer.