Polymer Coated Secondary Battery Case for Swelling Prevention
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Solution Overview
Problem
The manufacturing of secondary batteries is complex, leading to instability and issues such as incomplete electrolyte filling, increased volume due to empty spaces, and potential swelling from gas generation, which affects the battery's performance and reliability.
Innovation Solution
A method involving preparing an electrode assembly with protruding terminals, freezing it after electrolyte impregnation, dipping it in a liquid polymer material, and curing the polymer material to form a uniform layer that contacts the assembly, excluding the terminals, thereby reducing volume and preventing swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional manufacturing process is used, then the battery can be assembled, but incomplete electrolyte filling occurs and empty spaces remain, reducing reliability
Solution Approach 1:
The case and end caps are formed as a single integrated polymer material layer through dip-coating, eliminating separate assembly steps and ensuring complete sealing around the electrode assembly, which prevents electrolyte leakage and ensures complete filling
Solution Approach 2:
The polymer material layer is formed on the electrode assembly before final assembly completion. The dip-coating process creates a pre-formed sealed structure that automatically contains the electrolyte, eliminating the need for separate sealing operations and ensuring complete electrolyte distribution
2Volume of moving object
If empty spaces are present in the battery structure, then manufacturing is simpler, but the battery volume increases and swelling may occur due to gas generation
Solution Approach 1:
The polymer material layer integrates the case structure and sealing function into a single continuous component that completely surrounds the electrode assembly, eliminating empty spaces and potential gas accumulation zones, thereby reducing overall volume and preventing swelling
Solution Approach 2:
The polymer material layer forms a flexible yet sealed envelope around the electrode assembly, accommodating any volume changes while maintaining complete sealing, thus preventing gas-related swelling and reducing the need for additional buffer spaces
3Ease of manufacture
If the polymer material layer is applied without freezing, then the process is simpler, but the electrolyte solution leaks externally before polymerization
Solution Approach 1:
The electrode assembly is frozen before dip-coating with polymer material. This preliminary freezing action solidifies the electrolyte, preventing it from leaking during the coating process, while still allowing the polymer to form a complete seal around the assembly
Solution Approach 2:
The electrolyte solution undergoes phase transition from liquid to solid by freezing the electrode assembly before polymer coating. This phase change prevents electrolyte leakage during dipping, and the solidified electrolyte can later be re-liquefied through controlled warming after the polymer seal is established
4Productivity
If multiple separate components are used in manufacturing, then assembly is more flexible, but the manufacturing process becomes complex and unstable
Solution Approach 1:
The case, end caps, and sealing structures are merged into a single polymer material layer formed by dip-coating the electrode assembly. This integration eliminates multiple separate manufacturing steps and assembly operations, significantly improving productivity and process stability
Solution Approach 2:
The polymer material layer simultaneously performs multiple functions: structural containment (case), sealing (gasket), and electrical insulation. This multi-functionality consolidates what would traditionally require multiple separate components into a single manufacturing operation, enhancing both efficiency and reliability
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 method simplifies the manufacturing process, ensures complete electrolyte filling, reduces the battery's overall volume, and enhances stability by eliminating empty spaces and potential gas-related issues, resulting in a more reliable secondary battery.
Implementation Method 1
freezing the electrode assembly after an electrolyte solution is impregnated into the electrode assembly
Implementation Method 2
curing the liquid polymer material at an external surface of the electrode assembly after retrieving the electrode assembly
Data Source
AI summary
A secondary battery and a method of manufacturing the same are disclosed. In one aspect, the method includes preparing an electrode assembly comprising a positive electrode plate, a negative electrode plate, and a separator interposed therebetween. The method also includes freezing the electrode assembly after the electrode assembly is filled with an electrolyte solution, dipping the frozen electrode assembly in a liquid polymer material, retrieving the dipped electrode assembly from the liquid polymer material, and curing an external surface of the electrode assembly.