Lithium Polymer Battery Edge Insulation via Electrolyte Encapsulation
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Solution Overview
Problem
Lithium polymer batteries face issues with inadvertent short circuits between anode and cathode due to misalignment or exposure of current collectors, which existing solutions attempt to address but often add manufacturing steps or weight penalties.
Innovation Solution
A method and configuration where a current collector sheet is coated with electrode material on both surfaces and a polymer electrolyte is extruded or laminated to encapsulate one edge, leaving the other edge exposed to prevent short circuits while allowing for proper connection, using a conveyor mechanism and extrusion or lamination apparatuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating band or protruding separator is added to prevent short circuits, then reliability is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent combines the separator and insulating functions into a single integrated structure. The separator layers serve dual purposes: they provide ionic conductivity between electrodes while their lateral extensions beyond electrode edges provide electrical insulation to prevent short circuits. This eliminates the need for separate insulating bands or protruding structures, reducing manufacturing complexity while maintaining reliability.
2Ease of operation
If current collectors are fully exposed for connection, then ease of operation is improved, but risk of short circuit increases
Solution Approach 1:
The patent applies different properties to different regions of the current collector system. The central regions of current collectors remain exposed for electrical connection, while the edge regions are covered by laterally extending separator layers that provide insulation. This local differentiation allows simultaneous achievement of connection capability and short circuit prevention.
3Ease of manufacture
If misalignment is allowed in assembly, then ease of manufacture is improved, but short circuit risk increases
Solution Approach 1:
The patent incorporates lateral extensions of separator layers that protrude beyond the electrode edges before assembly is completed. These extensions act as a cushion or buffer zone that compensates for potential misalignment during assembly, maintaining reliable insulation even when components are not perfectly aligned, thus improving assembly tolerance without compromising safety.
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 configuration effectively prevents short circuits between anode and cathode while maintaining the structural integrity and connection capabilities of lithium polymer batteries, enhancing their reliability and manufacturing efficiency.
Implementation Method 1
a polymer electrolyte is extruded or laminated to encapsulate one edge
Implementation Method 2
a polymer electrolyte is extruded or laminated to encapsulate one edge
Data Source
AI summary
An electrochemical cell sub-assembly and a method for manufacturing same. The electrochemical cell sub-assembly includes a current collector sheet having a pair of opposite surfaces and a pair of opposite edges, each surface being coated with a respective layer of electrode material. A layer of polymer electrolyte envelopes both layers of electrode material and one of the pair of edges of the current collector sheet, thereby encapsulating the one edge of the current collector sheet white leaving exposed the other edge of the current collector sheet.