Battery Electrode Plate Insulation Layout for Substrate Crack Control

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Solution Overview

Problem

Insulating members in electrode plates for batteries can cause cracks in the electrode substrate, leading to quality defects, especially in lithium-ion secondary batteries.

Innovation Solution

The electrode plate design includes first and second insulating portions with protrusions that cover the electrode tab and substrate, preventing stress concentration and potential cracks by overlapping and aligning or crossing protrusions on opposite surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an insulating member is used to cover the electrode tab and substrate, then insulation is improved, but stress concentration and cracks in the electrode substrate occur

Engineering Contradiction:

ImproveinsulationVSAvoidelectrode substrate integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The insulating member incorporates protrusions at specific locations (first protrusions on the first surface, second protrusions on the second surface) to create localized stress-relief zones. This local structural modification allows the insulating member to maintain its insulating function while preventing stress concentration at critical areas where the electrode tab meets the substrate.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The protrusions of the insulating member are positioned in advance to overlap with the electrode substrate in a manner that preemptively distributes and cushions the stress before it can concentrate and cause cracks. The protrusions act as pre-positioned stress distributors that prevent harmful stress accumulation during battery operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Device complexity

If a simple insulating member is used, then device complexity is reduced, but stress distribution is insufficient leading to cracks

Engineering Contradiction:

Improveinsulating member structureVSAvoidcrack prevention

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Rather than making the entire insulating member complex, only specific protrusions are added at strategic locations (first and second surfaces). This localized structural enhancement maintains overall simplicity while providing the necessary stress distribution function to prevent cracks.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The insulating member is segmented into distinct protrusion features (first protrusions and second protrusions) that perform the stress distribution function independently. This segmentation allows the complex stress-management function to be achieved through discrete, manageable structural elements rather than a uniformly complex design.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250392026A1Electrode plate for battery and manufacturing method thereof

Publication Date: 2025.12.25 SAMSUNG SDI CO LTD

AI summary

An electrode plate for a battery includes: an electrode substrate; an electrode tab overlapping with a portion of the electrode substrate; a first insulating portion covering a portion of the electrode tab and a portion of the electrode substrate on a first surface, and including a plurality of first protrusions; and a second insulating portion covering a portion of the electrode tab and a portion of the electrode substrate on a second surface opposite to the first surface, and including a plurality of second protrusions.