Composite Laminated Cell Folding Structure for Electrode Alignment

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Solution Overview

Problem

Laminated battery cells face misalignment of negative and positive electrodes during manufacturing, leading to lithium plating, reduced cycle life, limited fast charging capacity, and safety risks such as combustion and explosion.

Innovation Solution

A thermal composite laminated cell design with partially cut structures on the separator and negative electrode, allowing for precise folding and alignment of electrodes without additional shaping processes, ensuring consistent folding quality and reducing lithium plating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If electrodes are folded in free fall during manufacturing, then manufacturing process is simple, but electrode alignment is poor

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidelectrode alignment

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The separator is pre-formed with folding guide structures (creases or slots) before assembly. These pre-defined guides determine the exact folding positions and orientations, ensuring that electrodes align properly during the folding process without requiring complex real-time control or additional shaping operations.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If shaping cylinders are used to clamp cells, then electrode alignment is improved, but manufacturing complexity increases and electrode damage risk increases

Engineering Contradiction:

Improveelectrode alignmentVSAvoidshaping process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The separator's folding guide structures enable the cell components to self-align and self-fold into the correct configuration during assembly. The structure itself provides the alignment function, eliminating the need for external shaping cylinders or complex clamping mechanisms, thereby reducing manufacturing complexity and electrode damage risk.

Inventive Principle:

Principle #25Self-service

3Productivity

If electrodes are misaligned, then manufacturing is easier, but lithium plating occurs and battery performance deteriorates

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidbattery cycle life

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If additional shaping processes are incorporated, then electrode alignment is improved, but manufacturing time increases

Engineering Contradiction:

Improveelectrode alignmentVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250316768A1Thermal composite laminated cell

Publication Date: 2025.10.09 EVE POWER CO LTD

AI summary

Disclosed herein is a thermal composite laminated cell comprising a negative electrode, a plurality of positive electrodes, and a separator, the separator comprising a first separator and a second separator, the negative electrode being attached to and between the first separator and the second separator to form a composite laminate comprising a plurality of body portions and a plurality of bending portions arranged alternately and continuously, the bending portions being provided with partially cut structures, the positive electrodes each being arranged between adjacent body portions in a thickness direction of the negative electrode, a projection in the thickness direction of the positive electrode falling completely within a planar area of the body portions. The present application overcomes the problem of poor alignment of the existing composite laminated cell, and has the advantages of good alignment and stable performance.