Folded Electrode Assembly for Faster Stacked Battery Production
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Solution Overview
Problem
The production efficiency of stacked batteries is low due to structural limitations, particularly in the stacking process, which hinders their development and application in energy storage systems and electric vehicles.
Innovation Solution
An electrode assembly with a first electrode plate folded in a Z-shape and a second electrode plate folded in a U-shape, allowing for orthogonal or parallel 'Z+U' stacking, which reduces the need for cutting and enhances stacking efficiency by alternately inserting multiple second laminates into the first laminate, thereby improving the production efficiency and safety of stacked batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional stacking methods are used for stacked batteries, then structural simplicity is maintained, but production efficiency is low due to time-consuming cutting processes
Solution Approach 1:
The electrode plates are divided into multiple laminates through folding, where the first electrode plate is folded into multiple first laminates and the second electrode plate is folded into multiple second laminates. This segmentation allows parallel processing and stacking without requiring extensive cutting operations, thereby improving production efficiency and reducing cutting time.
Solution Approach 2:
The second laminates are alternately stacked between the first laminates in a nested arrangement, creating a compact alternating structure. This nesting approach enables efficient space utilization and simplifies the stacking process by eliminating the need for separate cutting and assembly operations for each laminate, thus enhancing productivity while minimizing time loss.
2Adaptability or versatility
If electrode plates are extensively cut to create multiple laminates, then stacking flexibility is improved, but the risk of short circuits increases due to more cutting edges
Solution Approach 1:
Instead of cutting electrode plates into separate laminates, the invention uses folding to create multiple laminates from continuous electrode plates. This maintains stacking flexibility while minimizing the creation of cutting edges, thereby reducing the risk of short circuits associated with numerous cut surfaces.
Solution Approach 2:
Separators are introduced as intermediary elements between adjacent first laminates and second laminates. These separators prevent direct contact between positive and negative electrode laminates, effectively eliminating short circuit risks that would otherwise arise from the close proximity of multiple laminates with minimal cutting edges.
3Device complexity
If tabs are located on bending portions of electrode plates, then structural compactness is achieved, but tab damage occurs during folding reducing reliability
Solution Approach 1:
The invention applies different structural characteristics to different regions of the electrode plates. The bending portions are designed for structural compactness and flexibility, while the tab regions are positioned on flat portions to maintain tab integrity. This local differentiation ensures that each region performs its intended function without compromising overall reliability.
Solution Approach 2:
The electrode plate structure employs asymmetric tab positioning where tabs are located on flat portions rather than symmetrically on bending portions. This asymmetric arrangement protects tabs from damage during the folding process while maintaining the compactness of the bent structure, thereby preserving both structural integrity and electrical connection reliability.
4Manufacturing precision
If multiple cutting operations are performed to create laminates, then precise laminate dimensions are achieved, but manufacturing complexity and time increase
Solution Approach 1:
The electrode plates are pre-folded along predetermined lines to create laminates with precise dimensions before the stacking process. This preliminary folding action establishes the exact geometry and size of each laminate, eliminating the need for subsequent cutting operations to achieve precise dimensions, thereby simplifying the manufacturing process while maintaining high precision.
Solution Approach 2:
The invention replaces the mechanical cutting system with a folding system to create laminates. Folding operations are mechanically simpler and faster than cutting operations, yet they achieve the same result of creating precisely dimensioned laminates. This substitution reduces manufacturing process complexity and time while maintaining laminate dimension precision.
Data Source
AI summary
This application relates to the field of batteries, and in particular, to an electrode assembly and a manufacturing method therefor, a battery cell, a battery, and an electric apparatus. The electrode assembly may include: a first electrode plate, being folded back and forth in a first direction so that the first electrode plate includes a plurality of first laminates connected and stacked in sequence; and a second electrode plate, being opposite the first electrode plate in polarity and being folded once in a second direction so that the second electrode plate includes two second laminates connected to each other, where the second direction may be perpendicular or parallel to the first direction, and the second laminates and the first laminates may be alternately stacked in sequence.