Electrode with Round Corners for Flexible Battery Assembly

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Solution Overview

Problem

Existing electrode assemblies for pouch-shaped batteries are inflexible and difficult to adapt to various device shapes and sizes, leading to inefficient use of space and potential short circuits during manufacturing.

Innovation Solution

The electrode assembly is designed with unit cells of varying sizes stacked in a height direction, featuring round corners to accommodate different device shapes, and an insulative tape is used to prevent short circuits, with specific dimensions for the radii of curvature and unit cell sizes to ensure secure attachment and prevent electrode sheet breakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If electrode assemblies are designed with fixed rectangular shapes, then manufacturing is simple, but they cannot adapt to various device shapes and sizes

Engineering Contradiction:

Improveadaptability to various device shapesVSAvoidelectrode assembly structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The electrode assembly is divided into multiple unit cells with different planar sizes, allowing the overall assembly to be configured in various shapes by stacking different combinations of unit cells, thus adapting to different device forms without complicating the basic unit structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Unit cells are stacked in a height direction to create three-dimensional configurations, enabling the electrode assembly to achieve complex shapes and fit various device requirements while maintaining simple two-dimensional unit cell designs

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If insulative films are not properly attached to electrode leads, then manufacturing is faster, but short circuits occur between thermal welding device and electrode leads

Engineering Contradiction:

Improveprevention of short circuitsVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Insulative films are attached to electrode leads before the thermal welding process, preventing short circuits in advance. This preliminary protective action ensures reliability without significantly complicating the manufacturing sequence

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If unit cells have sharp corners, then cutting is easier, but electrode sheet breaks during manufacturing

Engineering Contradiction:

Improveelectrode sheet integrityVSAvoidcutting process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Corners of unit cells are designed to be round rather than sharp, distributing stress during cutting and handling operations to prevent electrode sheet breakage, while the rounding radius is controlled to maintain manufacturing efficiency

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Shape

If all unit cells have the same size, then manufacturing is standardized, but they cannot fit curved device shapes

Engineering Contradiction:

Improvefitting to curved device shapesVSAvoidmanufacturing efficiency

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The electrode assembly uses multiple unit cells with different planar sizes, enabling flexible configuration to match curved device shapes while each unit cell remains a standardized, easily manufacturable component

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different unit cells have different planar sizes tailored to specific locations within the device, allowing the electrode assembly to conform to curved surfaces and irregular device shapes while maintaining efficient manufacturing of individual standardized units

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9786874B2Electrode having round corner

Publication Date: 2017.10.10 LG ENERGY SOLUTION LTD

AI summary

Disclosed herein is an electrode assembly including two or more unit cells, each of which includes a cathode, an anode, and a separator disposed between the cathode and the anode, electrode tabs protruding from the respective electrodes, wherein the unit cells are stacked in a height direction on the basis of a plane, at least two of the unit cells having different planer sizes, and one or more corners of each of the unit cells, which do not tangent to one side of each of the unit cells at which the electrode tabs are formed, are round.