Secondary Battery Electrode Plate With Welded Protrusion And Elastic Protective Layer

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Solution Overview

Problem

Secondary battery electrode plates face challenges in enhancing energy density and safety performance due to poor current passing performance and structural rigidity issues, particularly when bending is required, which can lead to breakage or increased space occupation.

Innovation Solution

The electrode plate design includes a current collector with an insulating layer and conductive layers, featuring a protrusion portion uncovered by the active material layer, a conductive structure welded to the protrusion, and an elastic first protective layer between the welded zone and the active material layer, allowing for improved bending and reduced space occupation while maintaining current passing performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the current guiding portion and conductive structure are connected with a large length, then the current passing performance is improved, but the space occupation increases and energy density decreases

Engineering Contradiction:

Improvecurrent passing performanceVSAvoidspace occupation

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent changes the spatial arrangement by bending the current guiding portion and conductive structure in a folded configuration rather than extending them linearly. This dimensional transformation allows the current path to maintain sufficient length for good electrical connection while occupying minimal space within the battery assembly, directly resolving the contradiction between current passing performance and space occupation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If the protrusion portion is bent to reduce space, then the space occupation is reduced, but the protrusion portion breaks due to small thickness

Engineering Contradiction:

Improvespace occupationVSAvoidprotrusion portion strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The patent applies a protective layer on the surface of the protrusion portion before bending occurs. This protective layer acts as a cushion that prevents direct stress concentration on the thin protrusion portion during the bending process, thereby preventing breakage while allowing the necessary spatial reduction. The protective layer is applied in advance to anticipate and prevent the potential failure mode.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent utilizes a flexible protective film or coating on the protrusion portion that can accommodate the bending deformation. This thin film structure provides mechanical protection and flexibility simultaneously, allowing the protrusion portion to be bent into the folded configuration without breaking, thus resolving the contradiction between space reduction and structural strength.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the welded zone is positioned higher to avoid breakage, then the breakage risk is reduced, but the welded zone occupies large space at height

Engineering Contradiction:

Improvebreakage resistanceVSAvoidheight space occupation

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent resolves this contradiction by folding the current guiding portion and conductive structure horizontally rather than positioning the welded zone higher vertically. This dimensional change transforms the problem from a vertical space occupation issue to a horizontal folding configuration, allowing the welded zone to remain in an optimal position for strength while the overall structure occupies minimal height space through the folded arrangement.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design enhances energy density and safety performance by allowing the electrode plate to be bent without breaking and reducing the occupied space, thereby preventing short circuits and improving the overall efficiency of the secondary battery.

Implementation Method 1

The first protective layer has elasticity, and the first protective layer is disposed on a side of the protrusion portion facing away from the insulating layer

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The conductive structure is welded to the protrusion portion and thus a welded zone is formed

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11631862B2Electrode plate of a secondary battery and a secondary battery

Publication Date: 2023.04.18 CONTEMPORARY AMPEREX TECHNOLOGY (HONG KONG) LIMITED

AI summary

The present disclosure relates to a secondary battery and an electrode plate. The electrode plate includes a current collector, an active material layer, a conductive structure, and a first protective layer. The current collector includes an insulating layer and a conductive layer disposed on the insulating layer. The conductive layer includes a main body portion and a protrusion portion. A surface of the main body portion facing away from the insulating layer is covered by the active material layer, while a surface of the protrusion portion facing away from the insulating layer is uncovered by the active material layer. The conductive structure is welded to the protrusion portion and thus a welded zone is formed. The first protective layer has elasticity, and is disposed on a side of the protrusion portion facing away from the insulating layer and is located between the welded zone and the active material layer.