H-Shaped Slot Electrode Segmentation for Battery Edge Isolation
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Solution Overview
Problem
Existing battery manufacturing methods for high energy and power density lithium ion batteries face issues such as leakage current, short-circuiting, material loss, and unsatisfactory encapsulation, leading to reduced performance and increased costs.
Innovation Solution
The method involves stacking anode and cathode sheets with H-shaped slots, allowing for precise cutting and encapsulation, reducing the risk of short-circuits and material loss, and using a multilayer encapsulation system for improved protection and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If U-shaped slots are used in electrode sheets with lateral offset stacking, then production efficiency is improved, but leakage current and short-circuiting occur at the edges
Solution Approach 1:
The electrode sheets are segmented into main bodies and secondary bodies by transverse cutouts, creating distinct functional zones. The main bodies contain active materials for electrochemical reactions, while the secondary bodies are positioned to prevent edge-to-edge contact between opposing electrodes, thereby eliminating leakage current paths while maintaining high production efficiency through the U-shaped slot configuration.
Solution Approach 2:
An insulating material is introduced as an intermediary substance to fill the spaces created by the transverse cutouts at the edges of the battery. This insulating material physically separates the opposing electrode edges, preventing direct contact and short-circuiting while allowing the U-shaped slot configuration to maintain its production efficiency advantages.
2Manufacturing precision
If transverse cutouts are made through all electrodes, then encapsulation quality is improved, but material loss increases
Solution Approach 1:
The transverse cutouts are implemented locally only in the secondary bodies of the electrode sheets, rather than through the entire electrode structure. This localized approach provides sufficient encapsulation quality by creating separation zones where needed, while minimizing material loss by preserving the main bodies containing the active electrochemical materials.
3Strength
If thick encapsulation layer is deposited to ensure rigidity and protection, then structural integrity is improved, but encapsulation system becomes prone to delamination
Solution Approach 1:
The electrode structure is segmented into main bodies and secondary bodies with transverse cutouts, creating a modular architecture that provides structural rigidity without requiring excessive encapsulation thickness. The cutouts create natural separation zones that enhance the effectiveness of thinner encapsulation layers, preventing delamination while maintaining structural integrity.
Solution Approach 2:
The invention changes the geometric parameters of the electrode structure by introducing transverse cutouts and creating lateral offsets between main and secondary bodies. This structural parameter change allows for reduced encapsulation thickness while maintaining or improving both structural integrity and adhesion, as the cutouts provide inherent structural reinforcement and stress distribution.
Data Source
AI summary
Battery comprising at least one anode and at least one cathode, arranged on top of one another in an alternating manner, the battery comprising lateral edges and longitudinal edges, in which the anode comprises a current collector substrate, —at least one anode layer, and—optionally, a layer of an electrolyte material, and the cathode comprises: —a current collector substrate, at least one cathode layer, and—optionally a layer of an electrolyte material such that the battery comprises successively at least one anode layer, at least one layer of an electrolyte material and at least one cathode layer, characterized in that each anode and each cathode comprises a respective main body, separated from a respective secondary body by a space that is free of any electrode, electrolyte and/or current collector substrate material, the free space joining or extending between the opposite longitudinal edges of the battery.