Electrode Insulating Layer Thickness Control
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Solution Overview
Problem
Secondary batteries face issues with the deterioration of cycle performance due to excessive reduction of the insulating layer thickness during pressurization, leading to increased internal resistance and potential electrical short circuits.
Innovation Solution
A method for manufacturing electrodes with a laminated insulating layer that ensures a uniform thickness, at least twice the surface roughness Rz value of the electrode active material layer, to prevent localized thinning and enhance structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the insulating layer is pressurized to reduce thickness, then the internal resistance is reduced and battery performance is improved, but the insulating layer thickness becomes non-uniform and cycle performance deteriorates
Solution Approach 1:
The patent applies preliminary action by forming a smoothing layer on the electrode active material layer before laminating the insulating layer. This preprocessing step creates a flat surface that prevents excessive local thinning during subsequent pressurization, allowing the insulating layer to maintain uniform thickness and preventing electrical short circuits while still achieving low internal resistance
Solution Approach 2:
The smoothing layer acts as an intermediary between the electrode active material layer and the insulating layer. It mediates the interaction by providing a flat surface that distributes pressurization forces evenly, preventing direct contact between protrusions and the insulating layer that would cause localized thinning and short circuits
2Power
If the insulating layer thickness is reduced to improve battery performance, then the internal resistance decreases, but the risk of electrical short circuit increases
Solution Approach 1:
The smoothing layer is formed in advance to create a flat surface, ensuring that the insulating layer maintains sufficient thickness even when overall layer thickness is reduced. This preliminary surface preparation prevents localized thinning that would lead to electrical short circuits while allowing the use of thinner insulating layers for lower internal resistance
Solution Approach 2:
The smoothing layer provides localized quality improvement by creating a flat surface specifically at the interface between the electrode active material layer and the insulating layer. This local flattening ensures uniform insulating layer thickness distribution, preventing thin spots that could cause short circuits while maintaining overall thin layer design
Data Source
AI summary
A method for manufacturing an electrode having a laminated body including an insulating layer laminated on an electrode active material layer, said method comprising: a step of laminating an insulating layer on an electrode active material layer formed on a base, such that a thickness value of the insulating layer is at least twice a surface roughness Rz value of the electrode active material layer, the surface roughness Rz value being a ten point average roughness as measured in accordance with JIS B0601 1994.