Orthogonal Z-Folded Electrode Separator for Battery Pressure Distribution
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Solution Overview
Problem
Existing electrochemical cell technologies face challenges in achieving homogeneous pressure and force distribution during charge and discharge cycles, leading to reduced performance, safety, and lifetime, particularly in wound cells, while stacked cells are expensive and require precise alignment.
Innovation Solution
The electrochemical cell design involves a first electrode layer and a separator layer that are orthogonally z-folded, with a second electrode plate placed between the folded sections, allowing for easy alignment and reduced manufacturing costs, while maintaining a homogeneous pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If wound cell structure is used to increase charge capacity, then manufacturing cost is reduced and charge capacity is improved, but inhomogeneous pressure distribution occurs during charge and discharge
Solution Approach 1:
The cell structure is divided into multiple segments or layers that are stacked together. Each layer contains electrodes and separator arranged in a modular fashion, allowing independent compression and more uniform pressure distribution across the entire cell during charge and discharge cycles.
Solution Approach 2:
The patent transitions from a two-dimensional wound structure to a three-dimensional stacked configuration. This dimensional change allows for better pressure distribution by distributing mechanical stress across multiple layers and planes, rather than concentrating it in a single wound cylinder.
2Stress or pressure
If stacked cell structure is used to achieve homogeneous force distribution, then performance and safety are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent combines the advantages of both wound and stacked structures by integrating continuous material processing with layered assembly. Multiple layers are formed from continuous rolls and then stacked, maintaining manufacturing efficiency while achieving homogeneous force distribution characteristic of stacked cells.
Solution Approach 2:
The patent optimizes parameters such as layer thickness, material composition, and stacking configuration to achieve homogeneous force distribution. By carefully controlling these parameters, the cell structure can distribute stress uniformly without requiring complex alignment procedures or expensive equipment.
3Stress or pressure
If stacked cell structure is used for homogeneous force distribution, then performance is improved, but manufacturing precision requirements increase due to precise alignment needs
Solution Approach 1:
The patent designs universal interface features and standardized layer configurations that can be easily aligned and assembled. The modular structure includes built-in alignment guides and standardized connection points, allowing layers to be stacked with minimal precision requirements while still achieving homogeneous force distribution.
4Stress or pressure
If z-fold technique is used to improve pressure distribution, then homogeneous pressure distribution is achieved, but equipment complexity and manufacturing time increase
Solution Approach 1:
The patent incorporates pressure distribution features directly into the cell structure during the forming process, rather than requiring additional equipment to adjust pressure afterward. The layered design and material selection inherently promote homogeneous pressure distribution, eliminating the need for complex pressure regulation equipment.
Data Source
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AI summary
An electrochemical cell including a folded electrode layer and a folded separator, a battery including the electrochemical cell, and methods of forming the electrochemical cell and battery are disclosed. The electrode layer is folded in a first direction and the separator is folded in a second direction, such that the first direction and second direction are orthogonal each other.