Folded Electrode Assembly Without Tape Fixation Damage
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Solution Overview
Problem
Existing electrode assemblies in secondary batteries are prone to damage, such as wrinkles or swells, due to taping processes, and deintercalation of active materials, which affects production speed and alignment, and the tape may detach during electrolyte injection or degassing.
Innovation Solution
An electrode assembly design featuring a first electrode formed as a single sheet, repetitively in-folded and out-folded with a cover part covering exposed areas, and a second electrode interposed in spaces, along with a separator, eliminating the need for tape fixation and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tape is attached to fix the electrode assembly structure, then alignment is improved, but the electrode is damaged (wrinkles, swells, deintercalation)
Solution Approach 1:
The patent removes the harmful tape component from the electrode assembly structure. Instead of using tape to attach and align electrodes, the invention uses a folded separator structure that inherently maintains alignment without requiring external fixing materials, thereby eliminating the source of electrode damage.
Solution Approach 2:
The folded separator acts as an intermediary structure that provides mechanical support and alignment for the electrodes. By folding the separator to form a rigid framework, it mediates the structural requirements without introducing harmful external elements like tape that cause electrode damage.
2Device complexity
If simple stack type or lamination & stack type electrode assembly is used, then structure is simplified and electrolyte impregnation is improved, but production speed is slow and alignment is lowered
Solution Approach 1:
The separator is pre-folded into a rigid framework structure before electrode assembly. This preliminary action creates a self-aligning structure that speeds up the subsequent assembly process, as electrodes can be directly placed into the pre-formed pockets without requiring complex alignment procedures during manufacturing.
Solution Approach 2:
The folded separator divides the assembly space into distinct segmented pockets that naturally guide and position multiple electrode layers. This segmentation provides inherent alignment for each electrode layer, maintaining manufacturing precision while simplifying the assembly process and increasing production speed.
3Manufacturing precision
If tape is used to maintain alignment, then alignment is improved, but tape detaches during electrolyte injection or degassing process
Solution Approach 1:
The patent eliminates the tape component entirely by using the folded separator structure to provide inherent mechanical alignment. Without tape, there is no risk of detachment during electrolyte injection or degassing processes, as the alignment is maintained by the rigid folded structure of the separator itself.
4Productivity
If stack & folding type electrode assembly is used, then production speed and structural stability are improved, but process is complicated and alignment and electrolyte impregnation are lowered
Solution Approach 1:
The separator is pre-folded into the final rigid framework structure before electrode assembly, eliminating the need for complex post-assembly folding operations. This preliminary action simplifies the manufacturing process while maintaining high production speed, as electrodes are simply placed into the pre-formed structured pockets.
Data Source
AI summary
An electrode assembly according to an embodiment of the present invention for achieving the above object includes: a first electrode formed in the form of a single sheet and repetitively in-folded and out-folded at a predetermined interval; a second electrode provided in plurality and respectively interposed in spaces formed by folding the first electrode; a separator formed in the form of a single sheet and interposed between the first electrode and the second electrode so as to be repetitively in-folded and out-folded at a predetermined interval together with the first electrode; and a cover part configured to cover at least portions of an area, on which the separator is out-folded and an exposed surface, which is exposed to the outside together with the second electrode.