Perforated Laminated Battery Electrode for Better Electrolyte Flow

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Solution Overview

Problem

Traditional lithium-ion batteries suffer from poor electrolyte distribution and Li+ ion movement, leading to reduced performance and susceptibility to metal burring and shorting.

Innovation Solution

The battery electrodes are designed with a laminated foil structure comprising a polymer substrate and metal layers on either side, featuring perforations through the active material and metal layers to enhance electrolyte distribution and Li+ ion movement, while reducing metal burring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional solid electrode structure is used, then manufacturing is simpler, but electrolyte distribution and Li+ ion movement are poor

Engineering Contradiction:

Improveelectrolyte distributionVSAvoidelectrode structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electrode structure incorporates a porous intermediate layer between the active material layer and current collector. This porous structure creates channels that facilitate electrolyte penetration and Li+ ion transport throughout the electrode, directly addressing the poor electrolyte distribution and ion movement in traditional solid electrodes while maintaining structural integrity.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The electrode is divided into multiple functional layers: active material layer, porous intermediate layer, and current collector. This segmentation allows each layer to perform its specific function optimally - the porous intermediate layer specifically addresses electrolyte distribution and ion movement, while the other layers handle electrochemical reactions and electrical conduction.

Inventive Principle:

Principle #1Segmentation

2Reliability

If traditional electrode structure is used, then manufacturing is simpler, but metal burring and shorting occur

Engineering Contradiction:

Improveshorting preventionVSAvoidelectrode structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The porous intermediate layer serves as an intermediary between the active material layer and current collector. This intermediate layer prevents direct contact and potential shorting between metal components while still allowing efficient Li+ ion transport, thereby preventing metal burring and shorting without significantly complicating the manufacturing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The porous intermediate layer acts as a sacrificial or disposable component that prevents metal burring and shorting issues. While it adds a layer to the structure, it uses simple porous material that can be easily manufactured and integrated, providing a cost-effective solution to reliability problems.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS20260081182A1Battery electrode with layered structure and perforations

Publication Date: 2026.03.19 APPLE INC

AI summary

An electrode assembly includes an electrode having a laminated foil disposed between a first active material layer and a second active material layer, where the laminated foil includes a polymer substrate disposed between a first laminate layer and a second laminate layer. The electrode assembly also includes a plurality of perforations extending through the first active material layer, the second active material layer, and the laminated foil.