Electrode Assembly Opening Layout for Current Collector Durability
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Solution Overview
Problem
Electrochemical devices face issues such as wrinkles and fractures in current collectors during calendering and mechanical abuse, leading to reduced reliability and service life.
Innovation Solution
The electrochemical device design includes specific distance ranges between opening edges of the current collector to minimize tearing and damage, with overlapping regions for improved connection and buffering, and additional conductive regions for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductive plate is connected to the current collector during calendering, then electrical connection is achieved, but wrinkles and damage occur on the current collector surface
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the current collector at the connection positions before the calendering process. These recesses are created in advance to accommodate the conductive plate, so that during calendering the pressure is distributed evenly and does not concentrate on the exposed edges of the current collector, thereby preventing wrinkles and surface damage while ensuring reliable electrical connection.
2Reliability
If the conductive plate pulls the current collector during mechanical abuse, then electrical connection is maintained, but fractures occur in the current collector
Solution Approach 1:
The patent applies beforehand cushioning by designing the recesses with specific dimensions that create a buffer zone between the conductive plate and the main body of the current collector. During mechanical abuse such as drops, these recesses absorb and distribute the pulling forces, preventing stress concentration that would lead to fractures in the current collector while maintaining electrical connection reliability.
3Volume of moving object
If the opening edges are close together, then the device size is reduced, but tearing and damage risk increases
Solution Approach 1:
The patent applies local quality by creating localized recesses at specific positions on the current collector where the conductive plate connects. The recesses have optimized dimensions (depth and width) that provide local structural reinforcement exactly where needed - at the connection points and along the edges - allowing the overall device to remain compact while preventing tearing and damage at critical locations.
Data Source
AI summary
An electrode assembly includes a first electrode plate with a first current collector, a first conductive material layer provided with a first opening, and a second conductive material layer provided with a second opening. The first current collector includes a first surface and a second surface. The first surface includes a first region. The second surface includes a second region. When viewed from the first direction, the first region overlaps with the second region, and the first conductive plate is connected to the first region or the second region. The first opening includes first to third opening edges. The second opening includes fourth to sixth opening edges. The first, second, and third distances are the distances between the first-fourth, second-fifth, and third-sixth opening edges, respectively, the electrochemical device satisfies at least one of the following conditions: 0.2 mm≤first distance; 0.2 mm≤second distance; or 0.2 mm≤third distance.