Lithium Metal Electrode Assembly with Folded Separator Enclosure
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Solution Overview
Problem
Conventional electrode assemblies face issues with deformation due to stress accumulation during charge and discharge, leading to performance degradation and safety risks, particularly when using lithium metal as a negative electrode, and have low productivity due to difficulties in processing lithium metal.
Innovation Solution
A method of manufacturing a stackable-foldable electrode assembly by positioning a lithium metal layer between two separating films, cutting it to form a negative electrode tab, and joining the tab, minimizing lithium processing through ultrasonic cutting and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lithium metal layer is processed by conventional cutting methods, then negative electrode tab can be formed, but processing difficulty increases and defect rate increases
Solution Approach 1:
The patent applies preliminary action by positioning the lithium metal layer between two separating films before the winding process. This pre-positioning allows the lithium metal to be protected and properly aligned during subsequent manufacturing steps, reducing processing difficulty and defect rates when forming the negative electrode tab.
2Volume of moving object
If jelly-roll electrode assembly is wound densely, then space utilization improves, but stress accumulation causes deformation and safety issues
Solution Approach 1:
The patent uses separating films as intermediary elements between the lithium metal layer and other electrode components. These separating films act as buffers that reduce stress accumulation during charge-discharge cycles, preventing deformation while maintaining compact space utilization in the electrode assembly.
3Ease of manufacture
If stackable electrode assembly uses sequential stacking process, then electrode units can be assembled, but productivity decreases due to time-consuming processes
Solution Approach 1:
The patent merges the positioning and securing of the lithium metal layer into a single integrated step by placing it between two separating films. This combination of functions reduces the number of separate manufacturing steps required, thereby improving productivity while maintaining assembly feasibility.
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
This method reduces defect rates and improves productivity by minimizing lithium metal processing, ensuring a stable structure and efficient production of electrode assemblies.
Implementation Method 1
cutting it to form a negative electrode tab, and joining the tab, wherein the electrode assembly is a stackable-foldable electrode assembly
Implementation Method 2
joining the negative electrode tab
Data Source
AI summary
A method of manufacturing a stackable-foldable electrode assembly utilizing a negative electrode structure having a negative electrode comprising a lithium metal layer interposed between two separating films is provided. The method includes the steps of positioning a lithium metal layer to protrude in a width direction between two separating films, manufacturing a negative electrode structure by joining the lithium metal layer and the two separating films, laminating one positive electrode on the negative electrode structure, folding the negative electrode structure in the width direction to enclose the positive electrode, repeating the previous steps to manufacture an electrode laminate comprising a plurality of positive electrodes, cutting a portion of the lithium metal layer protruding in the width direction to form negative electrode tabs, and joining the negative electrode tabs. The method of manufacturing an electrode assembly may minimize processing of the lithium metal, thereby improving the productivity of the electrode assembly.