Electrode Plate Insulation Layout for Battery Edge Swelling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing high energy density batteries result in excessive thickness of the electrode plate coating, leading to edge swelling and material wastage, which affects the appearance and performance of the electrode plate.
Innovation Solution
An electrochemical device with an electrode plate featuring a first active material layer and an insulation layer with distinct thickness regions, where the thickness of the insulation layer towards the edge is reduced without extending to the active material layer, improving energy density and eliminating edge swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a relatively large coating weight is used on the electrode plate to increase battery capacity, then the battery energy density is improved, but the active material layer thickness increases causing obvious thickness steps at the edges affecting appearance
Solution Approach 1:
The insulation layer is designed with different thicknesses in different regions: a first thickness in the first region and a second thickness (greater than the first) in the second region. This local quality variation allows the edge portion to have sufficient insulation thickness for appearance while the central region maintains adequate insulation for electrical isolation, thus resolving the contradiction between edge appearance and overall insulation effectiveness.
2Reliability
If a thick insulation coating is applied to the electrode plate edge, then edge insulation is improved, but the thick edge causes edge swelling when wound and may break the electrode plate
Solution Approach 1:
The insulation layer thickness is locally optimized with a thinner first thickness in the first region and a thicker second thickness in the second region. This local differentiation provides sufficient insulation where needed while reducing excessive thickness that causes swelling, thereby maintaining both insulation reliability and structural integrity.
Solution Approach 2:
Instead of applying a uniformly thick insulation layer throughout, the patent inverts the approach by making the insulation layer thinner at certain regions (first region) and thicker at others (second region). This inverted thickness distribution resolves the contradiction by preventing edge swelling in the first region while maintaining insulation in the second region.
3Reliability
If the coating size of the insulation layer is increased to cover the electrode, then insulation coverage is improved, but material wastage increases due to cutting away the thick edge
Solution Approach 1:
The insulation layer is designed with spatially varying thickness, being thinner in the first region and thicker in the second region. This allows the insulation layer to provide adequate coverage and insulation performance while reducing the overall material consumption compared to a uniformly thick design, thus decreasing material wastage.
Data Source
AI summary
An electrochemical device includes an electrode plate, the electrode plate includes: a first current collector; a first tab protruding from the first current collector; a first active material layer disposed on at least one surface of the first current collector; and an insulation layer disposed along a side edge of the first current collector towards the first tab and abutted against the first active material layer. The insulation layer includes a first region and a second region, the first region is disposed towards the first tab, the second region is disposed away from the first tab and abutted against the first active material layer, and a thickness of the first region of the insulation layer is less than a thickness of the second region of the insulation layer.