Expanded Metal Core for Thick Non-Aqueous Electrolyte Battery
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Solution Overview
Problem
Conventional non-aqueous electrolyte batteries face issues with uniform charge-discharge reactions and high energy density due to the lattice shape of core materials becoming resistant during compression, leading to degraded battery performance and potential breakage of core materials under excessive stress.
Innovation Solution
A non-aqueous electrolyte battery design utilizing a positive electrode with an expanded metal core having a thickness of 0.8 mm to 3 mm, center-to-center distances in the mesh ranging from 6 mm^2 to 20 mm^2, and a feed width of 0.15 mm to 0.3 mm, which reduces stress and maintains high battery performance by ensuring uniform density and current collection properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the electrode is thickened to achieve high energy density, then the energy density is improved, but the charge-discharge reaction becomes non-uniform and battery performance degrades
Solution Approach 1:
The patent employs an expanded metal core material with a mesh structure that creates porous pathways throughout the electrode. This porous configuration allows electrolyte penetration and charge-discharge reactions to occur uniformly across the entire thick electrode volume, eliminating the non-uniform reaction problem while maintaining high energy density through the increased electrode thickness.
Solution Approach 2:
The expanded metal core provides locally optimized structural properties throughout the electrode. The mesh structure creates consistent local pathways for ion transport and electron collection at every position within the thick electrode, ensuring uniform reaction characteristics across the entire electrode volume rather than having uniform properties throughout.
2Quantity of substance
If the electrode is thickened to achieve high energy density, then the energy density is improved, but the core material may be stretched or broken due to excessive stress
Solution Approach 1:
The patent uses an expanded metal core with a flexible mesh structure that can accommodate compression forces during electrode assembly. The thin wire construction and open mesh configuration allow the core to flex and deform elastically under pressure, preventing stretching or breaking of the core material while still maintaining sufficient structural support for the thick electrode.
Solution Approach 2:
The porous mesh structure of the expanded metal core distributes applied compression stress across multiple pathways and joints, preventing stress concentration at any single point. This stress distribution mechanism allows the core to withstand the compression forces required for thick electrode assembly without exceeding the material's strength limits.
3Quantity of substance
If the electrode is thickened to achieve high energy density, then the energy density is improved, but the current collecting property decreases
Solution Approach 1:
The expanded metal core is segmented into a mesh structure with multiple interconnected pathways. This segmentation creates numerous distributed current collection points throughout the thick electrode volume, reducing the electrical resistance and improving current collecting properties compared to a solid core of equivalent outer dimensions.
Solution Approach 2:
The patent transitions from a traditional planar current collector to a three-dimensional expanded metal mesh structure. This dimensional change creates current collection pathways in multiple spatial directions, allowing electrons to reach the current collector from any position within the thick electrode through the shortest available path, thereby improving overall current collecting efficiency.
Data Source
AI summary
A non-aqueous electrolyte battery includes a positive electrode, a negative electrode, a separator interposed between the positive electrode and the negative electrode, and a nonaqueous electrolytic solution. The positive electrode, the separator, and the negative electrode are spirally wound. The positive electrode includes a positive electrode active material and an expanded metal. The positive electrode has a thickness larger than or equal to 0.8 mm and smaller than or equal to 3 mm. A thickness T of the expanded metal satisfies 0.15 mm≤T≤0.3 mm. A center-to-center distance SW of the expanded metal in a shorter direction in mesh and a center-to-center distance LW of the expanded metal in a longer direction in mesh satisfy 6 mm2≤LW·SW≤20 mm2. A feed width W of the expanded metal satisfies 0.15 mm≤W≤0.3 mm.