Electrode Laminate Edge Protection Against Separator Folding

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Solution Overview

Problem

Lithium secondary batteries face safety issues due to separator damage during assembly, leading to short circuits and potential ignition, particularly in stack/folding type batteries where corner portions of the separator are folded or torn, causing electrical short-circuits and voltage drop.

Innovation Solution

An electrode assembly with a protective block made of a first and second protective panel extending vertically from one longitudinal side, wrapping around the edge portions of the electrode laminate, combined with fixing tapes wound around the outer surfaces to prevent separator folding and damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the separator is not protected during assembly, then the manufacturing process is simple, but the separator may be folded or torn causing short circuits

Engineering Contradiction:

Improveseparator integrityVSAvoidassembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective block is installed on the electrode laminate before the stacking process begins, preventing separator damage from the outset rather than requiring post-assembly repairs or complex real-time monitoring systems

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protective block is divided into a first protective panel and a second protective panel that can be separately positioned and fixed, allowing for easier installation and adaptation to different electrode laminate sizes while maintaining comprehensive edge protection

Inventive Principle:

Principle #1Segmentation

2Reliability

If a protective block is added to wrap edge portions, then separator damage is prevented, but the device structure becomes more complex

Engineering Contradiction:

Improveshort circuit preventionVSAvoidprotective structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Protection is applied specifically at the edge portions of the electrode laminate where separator damage most commonly occurs, rather than covering the entire electrode assembly, thus providing targeted protection with minimal additional structure

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The protective block uses thin panel structures that provide adequate protection while maintaining flexibility for assembly and minimizing the overall volume increase of the battery pack

Inventive Principle:

Principle #30Flexible shells and thin films

3Productivity

If corner portions of the separator are not protected, then the assembly process is faster, but folding and tearing occur causing voltage drop

Engineering Contradiction:

Improveassembly speedVSAvoidelectrical continuity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The protective blocks are pre-positioned on the electrode laminate before stacking begins, eliminating the need for complex real-time monitoring and adjustment systems that would slow down production while ensuring corner protection

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20240030556A1Electrode Assembly

Publication Date: 2024.01.25 LG ENERGY SOLUTION LTD

AI summary

The electrode assembly of the present invention includes a protective block consisting of a first protective panel and a second protective panel extending vertically from one longitudinal side of the first protective panel at a) an edge portion in a full length direction of the electrode laminate, b) an edge portion in a full width direction, or c) at each of edge portions in the full length direction and the full width direction, thereby preventing a phenomenon in which the separator is folded.