Electrode Assembly Insulating Layer to Prevent Separator Curling
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Solution Overview
Problem
Internal short circuits can occur in batteries due to the cathode and anode contacting each other, and the use of a larger separator can lead to decreased energy density and curling from external impacts.
Innovation Solution
A battery design with an insulating layer on the cathode and a separator attached to the insulating layer, reducing the overhang and preventing contact between the cathode and anode, while maintaining similar sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the separator is formed in a size greater than the cathode and anode to prevent internal short circuits, then safety is improved, but energy density decreases due to inefficient space usage
Solution Approach 1:
The patent applies local quality by forming an insulating layer only in specific regions where short circuits are most likely to occur (edge regions and regions adjacent to the other electrode), rather than requiring the separator to overhang the entire electrode area. This localized protection maintains safety while reducing unnecessary separator material and improving energy density.
2Reliability
If the separator is formed in a size greater than the cathode and anode to prevent internal short circuits, then safety is improved, but device complexity increases due to separator curling from external impact
Solution Approach 1:
The patent applies preliminary anti-action by providing the insulating layer on the electrode in advance, which prevents the separator from curling due to external impacts. The insulating layer acts as a protective barrier that maintains separator flatness and prevents short circuits even under mechanical stress, eliminating the need for oversized separator design.
3Quantity of substance
If the separator is attached to the insulating layer in a size similar to the electrode, then energy density is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by forming the insulating layer on the electrode surface before attaching the separator. This pre-formed insulating layer provides a defined attachment surface that guides precise separator placement, reducing manufacturing complexity while maintaining the benefit of reduced separator overhang and improved energy density.
Data Source
AI summary
A battery includes an electrode assembly including a cathode including a cathode collector, a cathode active material layer provided in a first region of a surface of the cathode collector, and an insulating layer provided in a second region of the surface of the cathode collector and adjacent to the cathode active material layer, an anode including an anode collector and an anode active material layer provided in a region of a surface of the anode collector and a separator provided between the cathode and the anode. At least a portion of the separator is configured to be attached to at least a portion of the insulating layer.