Foldable Electrode Assembly for Z-Axis Battery Stacking
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Solution Overview
Problem
Existing electrode assemblies face issues with active materials breaking due to bending forces and non-uniform electric field distribution, leading to limitations in maximum permissible voltage and energy density, especially in vertically stacked zigzag configurations.
Innovation Solution
The electrode assembly is designed with a belt current collector and glue frame to prevent active material breakage, allowing vertical zigzag stacking with sealed electrochemical systems that only transfer charge without electrochemical reactions, using a glue frame and belt current collectors to form bending portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a plurality of electrochemical systems are connected in series or parallel with tabs, then the battery device can achieve required voltage and capacity, but the space configuration loses energy density and the structure becomes complex
Solution Approach 1:
The patent merges multiple electrochemical systems into a single integrated pouch structure where individual cells are stacked and connected internally. The glue frame integrates multiple functions (structural support, electrical connection, sealing) into one component, reducing the number of separate tabs and connections needed, thereby improving space utilization and energy density.
Solution Approach 2:
The patent transitions from a two-dimensional tab-based connection system to a three-dimensional stacked configuration. By stacking electrochemical systems vertically within the pouch and using the glue frame for vertical integration, the design optimizes space in the z-dimension, reducing the footprint and improving energy density.
2Power
If multiple tabs are configured for series or parallel connections, then electrical connectivity is achieved, but the device complexity increases
Solution Approach 1:
The glue frame combines multiple functions into a single component: it provides structural support for stacking, creates electrical connections between adjacent electrochemical systems, and enables series or parallel configurations. This integration eliminates the need for multiple separate tabs and connection elements, significantly reducing structural complexity.
Solution Approach 2:
The glue frame serves multiple purposes simultaneously: it acts as a structural support element, an electrical conductor for connecting cells, and a positioning feature for assembly. This multi-functionality reduces the number of separate components needed, simplifying the overall device structure while maintaining required electrical connectivity.
3Ease of manufacture
If electrochemical systems are stacked without a enclosing structure, then mass production is facilitated, but the systems lack protection and proper alignment
Solution Approach 1:
The pouch structure integrates protection, alignment, and structural support functions into a single enclosing component. It protects the stacked electrochemical systems from environmental damage, maintains proper alignment through its rigid structure, and facilitates mass production by providing a unified assembly that can be manufactured and assembled efficiently.
Solution Approach 2:
The pouch structure acts as a flexible yet protective enclosure that contains the stacked electrochemical systems. It provides mechanical protection while allowing for the compact stacked configuration, and its design facilitates automated assembly processes for mass production while ensuring reliable protection and alignment of internal components.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C
AI summary
The invention provides an electrode assembly and its battery device thereof, which is composed of a first belt current collector and a second belt current collector, which a plurality of electrochemical systems are disposed therebetween. Also, the glue frame is utilized to completely enclose thereof. Therefore, each electrochemical system is an independent module and there only have charges transferred occurring rather than electrochemical reactions therebetween. The glue frame located between the electrochemical systems and the first belt current collector and the second belt current collector adhered by the glue frame can be folded to form a bending portion. By the bending portion, the electrochemical system would be folded to overlap the adjacent electrochemical system to achieve a z-axis stacking. It is easy to mass produce, and it can also reduce the amount of the tabs configured in series or parallel. Therefore, the energy density loss of the space configuration can be reduced.