Multilayer Electrode Assembly for Short-Circuit Isolation
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Solution Overview
Problem
Existing electrode assemblies in secondary batteries are prone to short circuits and explosions due to single-layered structures, which lack effective insulation and require separate connection parts for electrode leads, posing safety risks.
Innovation Solution
The electrode assembly is manufactured with a multilayered structure that includes electrode insulating layers, allowing for easy connection of electrode leads to multiple tabs without separate connection parts by etching the insulating layers using an organic solvent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layered electrode structure is used, then the manufacturing process is simple, but short circuits occur on both surfaces when damaged causing explosion risks
Solution Approach 1:
The electrode structure is divided into multiple layers: a first electrode foil, an insulating layer, and a second electrode foil. This segmentation creates independent electrical pathways, so that if one surface experiences damage, the insulating layer prevents short circuits by isolating the damaged area from the opposite electrode surface.
Solution Approach 2:
The insulating layer is pre-installed between the first and second electrode foils to provide beforehand protection against short circuits. This cushioning layer is positioned in advance to absorb or prevent harmful electrical contact that might occur due to external impacts or damage during battery operation.
2Reliability
If separate connection parts are used to connect electrode leads to tabs, then connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The connection structure merges the electrode tab with the electrode foil by extending the electrode foil to form the tab. This eliminates the need for separate connection parts, as the tab itself serves as the connection interface for attaching electrode leads, thereby reducing device complexity while maintaining connection reliability.
Solution Approach 2:
The electrode tab serves multiple functions: it acts as both the electrical conductor and the mechanical connection point for electrode leads. This multi-functionality eliminates the need for dedicated connection components, simplifying the overall structure while ensuring reliable electrical and mechanical connection.
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 multilayered structure with insulating layers effectively prevents short circuits and explosions by ensuring electrical disconnection upon impact, simplifying the connection process and reducing manufacturing complexity and cost.
Implementation Method 1
a step of respectively removing the positive electrode insulating layer and the negative electrode insulating layer from at least partial areas of a positive electrode tab
Data Source
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AI summary
A method for manufacturing an electrode assembly according to an embodiment of the present invention for solving the above problems includes: a step of applying a positive electrode active material to at least a portion of a positive electrode collector, which is formed by sequentially stacking a first positive electrode foil, a positive electrode insulating layer, and a second positive electrode foil, to manufacture a positive electrode and applying a negative electrode active material to at least a portion of a negative electrode collector, which is formed by sequentially stacking a first negative electrode foil, a negative electrode insulating layer, and a second negative electrode foil, to manufacture a negative electrode; a step of interposing a separator between the positive electrode and the negative electrode; a step of respectively removing the positive electrode insulating layer and the negative electrode insulating layer from at least partial areas of a positive electrode tab, which is not coated with the positive electrode active material in the positive electrode collector, and an negative electrode tab, which is not coated with the negative electrode active material in the negative electrode collector; and a step of connecting a positive electrode lead and a negative electrode lead to the positive electrode tab and the negative electrode tab, respectively.