Secondary Battery Electrode Structure with Integrated Resin Mass
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Solution Overview
Problem
Conventional secondary battery separators made of resin films face challenges in achieving high volumetric energy density due to mechanical strength requirements, and organic fiber deposits can lead to internal short circuits if not properly integrated with the active material-containing layers.
Innovation Solution
An electrode structure incorporating an organic fibers-including layer with a resin mass that is integrated with the active material-containing layer, providing a binding point and increased contact area to prevent peeling and enhance adhesion, thereby reducing the risk of internal short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separator made of resin film is used, then mechanical strength is sufficient to prevent breaking during battery production, but the separator thickness cannot be reduced below a certain extent, limiting volumetric energy density improvement
Solution Approach 1:
The invention changes the material parameters by transitioning from conventional resin films to organic fiber deposits, fundamentally altering the structural and mechanical properties of the separator to achieve both thinness and sufficient strength
Solution Approach 2:
The invention uses composite materials by combining organic fibers with specific resin compositions to create a separator that achieves both reduced thickness and maintained mechanical strength through the synergistic properties of the composite structure
2Strength
If the thickness or density of the separator is excessively large, then mechanical strength is improved, but rapid movement of lithium ions between electrodes is inhibited, deteriorating input and output performance
Solution Approach 1:
The invention optimizes the physical and chemical parameters of the separator by controlling fiber diameter, porosity, and resin content to achieve the optimal balance between mechanical strength and lithium ion conductivity
Solution Approach 2:
The invention employs porous organic fiber deposits with controlled porosity to provide both mechanical strength and sufficient pathways for rapid lithium ion transport, resolving the contradiction between strength and ion mobility
3Volume of stationary object
If organic fiber deposits are used as separator, then film thickness can be reduced below that of self-supporting film type separators, but internal short circuit may occur when portions of the organic fiber deposits peel off from active material-containing layers or electrode tabs
Solution Approach 1:
The invention introduces a resin component as an intermediary material that bonds the organic fiber deposits to the active material-containing layers and electrode tabs, preventing peeling and ensuring reliable electrical connection
Solution Approach 2:
The invention creates a composite structure where organic fibers provide mechanical framework and adhesion promoters enhance bonding, achieving both thinness and peeling resistance through the synergistic combination of materials
Data Source
Figure 1~3
Figure 4~5
Figure 6(a)~6(e)
AI summary
According to one embodiment, an electrode structure (10) is provided. The electrode structure (10) includes an electrode (20) and a separator (22). The electrode (20) includes an active material-containing layer (20b). The separator (22) includes a layer (23) provided on a main surface (S1) of the active material-containing layer (20b). The layer (23) includes organic fibers (231) and a resin mass (232). The resin mass (232) is in contact with a portion of the main surface (S1) of the active material-containing layer (20b). The resin mass (232) is integrated with a portion of the organic fibers (231). When a length of the resin mass (232) is represented by a circumscribed quadrilateral of the resin mass (232), a length of a first side of the circumscribed quadrilateral and a length of a second side adjacent to the first side are each 10 µm or more.