Jelly Roll Tape with Oriented Polystyrene Film
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Solution Overview
Problem
Conventional jelly roll tapes for rechargeable batteries lack sufficient adhesiveness and stability, leading to electrode assembly movement within the battery case, potential short-circuits, and damage due to external impacts, especially in polymer batteries where they shrink and lose adhesiveness when reacting with electrolytes.
Innovation Solution
A jelly roll tape with a rubber-based adhesive layer and an electrolyte-insoluble film, applied as a seal tape to the electrode assembly, maintaining adhesiveness and preventing movement, comprising an oriented polystyrene film with a tensile strength of 200-600 kgf/cm2 and an electrolyte-insoluble film like PET, PI, or PP, which does not dissolve in the electrolyte, ensuring stability and preventing shrinkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional jelly roll tape is used for the electrode assembly, then the battery can be assembled, but the adhesive tape shrinks and loses adhesiveness when reacting with electrolytes, causing the electrode assembly to move within the battery case
Solution Approach 1:
The jelly roll tape is divided into multiple functional layers: a base film layer (oriented polystyrene) that provides dimensional stability and does not shrink, and a separate adhesive layer that provides bonding strength. This segmentation allows each layer to perform its specific function without interfering with the other, resolving the contradiction between maintaining adhesiveness and preventing shrinkage.
Solution Approach 2:
The invention uses a composite structure combining oriented polystyrene film (which has high tensile strength and dimensional stability with 200-600 kgf/cm²) as the base layer, topped with a rubber-based adhesive layer. This composite material approach allows the non-shrinking base layer to maintain dimensional stability while the adhesive layer provides continuous bonding strength even after electrolyte exposure.
2Reliability
If the adhesive tape reacts with the electrolyte to develop adhesiveness, then the tape can bond to the electrode assembly, but the tape shrinks and causes local changes in battery thickness
Solution Approach 1:
By separating the adhesive function into a distinct adhesive layer applied on top of the oriented polystyrene base film, the invention ensures that the base film does not shrink while the adhesive layer provides bonding. This prevents local thickness changes because the stable base film maintains uniform dimensions while the adhesive layer conforms to the electrode assembly surface.
Solution Approach 2:
The invention changes the material parameters of the base film to have extremely low shrinkage characteristics (oriented polystyrene with 200-600 kgf/cm² tensile strength), while the adhesive layer is designed to react with electrolyte to develop optimal bonding strength. This parameter optimization resolves the contradiction between bonding strength and thickness uniformity.
3Reliability
If the jelly roll tape does not have sufficient adhesiveness, then the battery structure remains simple, but the electrode assembly moves within the battery case leading to potential short-circuits
Solution Approach 1:
The jelly roll tape is segmented into a simple oriented polystyrene base film layer and a rubber-based adhesive layer. This segmentation achieves high reliability in preventing electrode assembly movement through the combined properties of the two layers, while keeping the overall structure relatively simple and easy to manufacture.
4Object-affected harmful factors
If the jelly roll tape lacks shock resistance, then the battery can be manufactured easily, but the edge portions of the battery are vulnerable to damage due to external impact
Solution Approach 1:
The invention uses a composite structure where the oriented polystyrene base film provides high tensile strength (200-600 kgf/cm²) and dimensional stability for shock resistance, while the rubber-based adhesive layer provides flexibility and bonding. This composite approach enhances shock resistance at edge portions without significantly complicating the manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances battery stability and shock resistance by maintaining adhesiveness even after contact with the electrolyte, preventing electrode assembly movement and local thickness changes, thus improving battery performance and lifespan.
Implementation Method 1
an adhesive layer formed on at least one surface of the adhesive tape, wherein the adhesive layer is a rubber-based adhesive layer
Implementation Method 2
The adhesive tape may be an oriented polystyrene (OPS) film. The OPS film has a tensile strength in the range of about 200 kgf/cm2 to about 600 kgf/cm2
Implementation Method 3
The jelly roll tape may further include an electrolyte insoluble film that is not dissolved in the electrolytic solution, the electrolyte insoluble film formed between the adhesive tape and the adhesive layer formed on at least one surface of the adhesive tape
Data Source
AI summary
A jelly roll tape for a rechargeable battery and a rechargeable battery having the same are disclosed. In one aspect, the jelly roll tape includes a first adhesive layer configured to develop an adhesive property based at least in part on a reaction with an electrolytic solution and a second adhesive layer formed on at least one surface of the first adhesive layer. The second adhesive layer is formed at least partially of a rubber-based material.