Electrode Insulator Layout for Higher-Energy Electrochemical Cells
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Solution Overview
Problem
The existing electrochemical devices face a reduction in energy density due to the insulating adhesive film covering part of the active material layer, which affects the capacity and safety by potentially causing short circuits.
Innovation Solution
An electrochemical device design where the insulator is configured to minimize the area covered by the active material layer while reliably covering the connecting edges, thereby increasing the effective area of the active material layer, using a base portion and extending portions that cover the edges of the first electrode plate, ensuring safety and enhancing energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating adhesive film is provided between the active material layer and the blank foil region to prevent short circuit, then safety is improved, but the capacity and energy density are reduced due to coverage of active material layer
Solution Approach 1:
The insulator is divided into a base portion and an extending portion that separately cover different regions (connecting edge and side edge respectively), allowing precise coverage of only the necessary insulating areas while minimizing coverage of active material layer
Solution Approach 2:
The insulator provides different coverage functions in different locations: the base portion covers the connecting edge where short circuit risk is highest, while the extending portion extends to cover the side edge, creating localized insulation exactly where needed without unnecessary coverage of active material
2Reliability
If the insulator covers the connecting edge and side edge to ensure safety, then reliability is improved, but the effective area of active material layer is reduced
Solution Approach 1:
The insulator extends beyond the minimum required coverage area to include both the connecting edge and side edge, providing excessive coverage in terms of safety margin while still maintaining larger effective active material area compared to conventional full-surface insulation approaches
Data Source
AI summary
An electrochemical device includes an electrode assembly and an insulator. The electrode assembly includes a first electrode plate, a second electrode plate and a separator. The first electrode plate includes a first current collector and a first active material layer. The first active material layer is provided with a first connecting edge. A first blank foil region is provided on a first surface of the first electrode plate. The insulator covers a part of the first active material layer and a part of the first blank foil region, respectively.