Electrode Insulation Reliability via Porous Layer Roughness Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrochemical elements face challenges in achieving reliable insulation between electrodes, particularly in high-temperature environments, which can lead to short circuits and reduced capacity retention due to the lack of effective insulation layers.
Innovation Solution
The implementation of an electrode structure that includes an electrode composite layer with an active material and a porous insulating layer on top, where the surface roughness of the composite layer is smaller than the average film thickness of the insulating layer, enhancing insulation reliability without the need for additional surface smoothing layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a ceramic separator layer is provided on the electrode surface to improve heat resistance and safety, then thermal stability is improved, but the surface roughness increases which may compromise insulation reliability
Solution Approach 1:
The patent applies nesting by placing the surface smoothing layer on top of the ceramic separator layer. The rough surface of the ceramic layer (which provides heat resistance) is nested within the overall electrode structure, while the smoothing layer is added on the outer surface to compensate for the roughness. This nested configuration allows both the heat-resistant ceramic layer and the insulation-reliable smoothing layer to coexist without compromising either function.
2Reliability
If additional surface smoothing layers are added to improve insulation reliability, then insulation reliability is improved, but the number of layers and device complexity increases
Solution Approach 1:
The surface smoothing layer serves multiple functions simultaneously: it provides electrical insulation between electrodes, smooths the surface for better contact with adjacent components, and maintains structural integrity. By making this single layer multi-functional, the patent avoids the need for separate dedicated insulation layers, thus improving reliability without proportionally increasing the number of layers.
3Reliability
If the porous insulating layer thickness is increased to improve insulation, then insulation reliability is improved, but the overall electrode thickness and device volume increase
Solution Approach 1:
The patent applies local quality by creating a surface smoothing layer with specific localized properties on the electrode surface. This layer has controlled thickness and porosity optimized for insulation purposes, while the bulk of the electrode maintains its original structure and thickness. The insulation enhancement is achieved locally at the surface where it is most needed, rather than uniformly throughout the entire electrode volume.
Data Source
AI summary
In accordance with some embodiments of the present invention, an electrode was provided. The electrode includes an electrode composite layer and a porous insulating layer on the electrode composite layer. The electrode composite layer contains an active material. A surface roughness Rz of the electrode composite layer is smaller than an average film thickness of the porous insulating layer.