Electrode Assembly Winding with Segmented Separator
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Solution Overview
Problem
In high capacity secondary batteries, accurately aligning unit electrodes with separators becomes challenging as the number of winding turns increases, leading to difficulties in manufacturing efficient electrode assemblies.
Innovation Solution
The electrode assembly is manufactured by winding a separator with electrodes positioned between stacked separator members, where the central separator is bent and electrodes are aligned perpendicular to the separator members, allowing for precise alignment through adjustable distances and symmetrical winding, reducing the number of turns and ensuring accurate electrode placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of winding turns increases to achieve high capacity, then the battery capacity increases, but the alignment accuracy between unit electrodes and separators deteriorates
Solution Approach 1:
The separator is divided into multiple stacked separator members, with unit electrodes positioned between them. This segmentation allows each layer to be aligned independently, maintaining alignment accuracy even as the total number of turns increases for high capacity batteries.
Solution Approach 2:
The patent transitions from a simple linear winding structure to a three-dimensional stacked structure with multiple separator members and unit electrodes arranged in layers. This dimensional change enables better control over alignment in the radial direction, solving the alignment accuracy problem while maintaining high capacity through increased winding turns.
2Quantity of substance
If the number of winding turns increases, then the battery capacity increases, but the manufacturing complexity increases
Solution Approach 1:
By segmenting the separator into multiple stacked members and positioning unit electrodes between them, the patent creates a modular structure that simplifies the winding process. Each layer can be assembled systematically, reducing manufacturing complexity despite the increased number of turns required for high capacity.
Solution Approach 2:
Unit electrodes are pre-positioned between stacked separator members before the winding process begins. This preliminary arrangement simplifies the subsequent winding operation, making the manufacturing process more manageable even as the number of turns increases to achieve high capacity.
3Manufacturing precision
If unit electrodes are positioned between stacked separator members with central separator bent, then alignment accuracy improves, but the device complexity increases
Solution Approach 1:
The central separator member is bent asymmetrically to create a specific curvature that facilitates alignment. This asymmetric bending of the central separator, while adding some structural complexity, enables precise alignment of unit electrodes with separators, improving manufacturing precision significantly.
Solution Approach 2:
The central separator is bent into a curved or arc-shaped configuration rather than remaining flat. This curvature helps in achieving better alignment between unit electrodes and separators during the winding process, improving alignment accuracy while the added structural complexity is managed through the systematic stacked arrangement.
Data Source
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AI summary
An electrode assembly for a secondary battery and a method of manufacturing the same are disclosed. The electrode assembly is made by winding a separator around positive and negative electrodes starting from a central portion of the separator, so that the electrodes can be accurately aligned. The positive and negative electrodes can be arranged along the length of the separator prior to winding.