Electrode Sheet Insulating Layer Layout for Burr-Tolerant Cutting
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Solution Overview
Problem
The insulating layer on electrode sheets in battery manufacturing has poor compatibility with burrs formed during cutting, leading to a high risk of short circuits due to burrs piercing the separator, especially when the insulating layer is thin and uniformly thick.
Innovation Solution
The insulating layer is designed with a first insulating portion and a second insulating portion, where the second portion has a greater thickness than the first, and the ratio of thicknesses is optimized to improve compatibility with burrs, reducing the risk of piercing the separator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the insulating layer has a uniform thin thickness to reduce electrode sheet thickness and improve energy density, then the energy density is improved, but the compatibility with burrs deteriorates and the risk of separator piercing increases
Solution Approach 1:
The insulating layer is designed with different thicknesses in different regions: a first thickness in the first region and a second thickness greater than the first thickness in the second region. This local quality variation allows the insulating layer to maintain thin overall thickness for high energy density while providing enhanced burr compatibility in the cutting region through increased local thickness.
2Length of moving object
If the insulating layer is made thinner to reduce electrode sheet thickness, then the thickness reduction is achieved, but the ability to prevent burrs from piercing the separator deteriorates
Solution Approach 1:
The insulating layer transitions from uniform thickness to non-uniform thickness with a thicker second region specifically positioned in the cutting area. This local thickness enhancement provides better burr containment capability where cutting occurs, while maintaining overall thinness for reduced electrode sheet thickness.
Solution Approach 2:
The insulating layer is pre-designed with a thicker second region before cutting occurs. This preliminary structural preparation ensures that when cutting and burr formation happen, the enhanced thickness is already in place to prevent burrs from piercing the separator, rather than attempting to address the issue after burrs are formed.
3Ease of manufacture
If the insulating layer has uniform thickness to facilitate rolling, then the rolling process is simplified, but the compatibility with burrs after cutting deteriorates
Solution Approach 1:
The insulating layer is designed with localized thickness variation where only the second region has increased thickness while the first region maintains thinner thickness. This targeted approach provides burr compatibility enhancement only where needed in the cutting area, while keeping other areas thin for overall manufacturing efficiency and rolling facilitation.
Data Source
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AI summary
An electrode sheet, a battery, and an electrode sheet processing method. The electrode sheet comprises a current collector, an active layer, and a first insulating layer. The first insulating layer and the active layer are both coated on a first surface of the current collector, and the first insulating layer comprises a first insulating portion and a second insulating portion. The first insulating portion has a first side edge and a second side edge which are oppositely arranged, the first side edge abuts against the active layer, and the second side edge abuts against the second insulating portion. The second insulating portion is used for cutting processing. Since the first insulating portion is arranged between the second insulating portion and the active layer, and a second thickness b of the second insulating portion is greater than a first thickness a of the first insulating portion, the second insulating portion has a larger thickness, and after cutting, the second insulating portion can effectively improve the compatibility of the insulating layer with burrs formed on a cut surface, thereby reducing the risk of the burrs piercing a separator.