Non-Rectangular Battery Electrodes with Segmented Insulation

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Solution Overview

Problem

Conventional lithium battery electrodes with linear insulating coatings restrict tab placement to a single side, leading to increased battery volume, longer cable runs, and resistance, which can cause thermal events due to sharp edges or burs on common tabs.

Innovation Solution

Non-rectangular shaped electrodes with complex insulation coatings allow tab placement on multiple sides, reducing battery volume, improving packaging efficiency, and preventing short circuits by distributing insulation along the periphery of the electrodes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a linear strip of insulating material is used to coat the electrode, then the common tab is protected from shorting, but the tab placement is restricted to a single side and battery volume increases

Engineering Contradiction:

Improveprotection from shortingVSAvoidbattery volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The insulating coating is segmented into multiple discrete regions positioned at different locations around the electrode periphery, allowing tabs to be placed on multiple sides rather than being constrained to a single linear strip location

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating coating transitions from a one-dimensional linear strip to a two-dimensional multi-region distribution around the electrode, enabling tab placement on multiple sides and reducing the need for extended cable runs

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If a linear strip of insulating material is used, then shorting is prevented, but cable run length increases and resistance increases

Engineering Contradiction:

Improveprevention of short circuitsVSAvoidcable run length

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

Insulating regions are placed locally at specific periphery locations where tabs will be positioned, providing protection exactly where needed rather than requiring a continuous linear strip that extends cable run distance

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If complex shaped insulation coating is used, then tab placement flexibility increases, but manufacturing complexity increases

Engineering Contradiction:

Improvetab placement flexibilityVSAvoidinsulation coating complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The complex insulation pattern is achieved through segmentation into multiple simple geometric regions rather than requiring a single complex continuous shape, simplifying the coating process while maintaining tab placement flexibility

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11404682B2Non-rectangular shaped electrodes utilizing complex shaped insulation

Publication Date: 2022.08.02 APPLE INC

AI summary

The disclosed technology relates to electrodes of a battery cell. The electrodes include a current collector having a first non-rectangular shape, an active coated region having a second non-rectangular shape, an insulator coated region having a third non-rectangular shape, and an uncoated tab disposed adjacent to the insulator coated region. The insulator coated region is disposed along a periphery of the current collector along a plurality of sides or edges of the current collector providing several locations for the tab to be positioned.