Porous Insulated Electrode Substrate for Direct Terminal Welding
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Solution Overview
Problem
Conventional composite substrates for rechargeable lithium batteries face issues with electrical connectivity and short circuits due to insulating layers, leading to assembly challenges and increased substrate tab lengths.
Innovation Solution
An electrode substrate with an insulating layer having an interconnected pore structure, allowing direct electrical connection of metal layers via a strip terminal without a separate substrate tab, reducing short circuits and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a general substrate tab is used to attach to one surface of each metal layer and then connect the strip terminal, then electrical connectivity is achieved, but the length of the substrate tab increases making assembly difficult and causing short circuits
Solution Approach 1:
The insulating layer is divided into a first region and a second region, with the first region containing metal that fills the pore structure to enable electrical connection. This segmentation allows the strip terminal to be directly attached to the current collector without requiring a long substrate tab, as the electrical connection is achieved through the metal-filled pores in the insulating layer.
Solution Approach 2:
Instead of extending the substrate tab in one dimension (length), the patent creates electrical connection pathways through the thickness dimension by filling the pore structure of the insulating layer with metal. This allows the strip terminal to connect to both metal layers through the insulating layer without requiring a long tab extension.
2Object-affected harmful factors
If an insulating layer is used in the composite substrate, then short circuits during penetration are prevented, but electrical connectivity between metal layers is compromised when strip terminal is directly attached
Solution Approach 1:
The insulating layer has different properties in different regions: the first region contains metal that fills the pore structure to provide electrical connectivity, while the second region maintains the insulating pore structure to prevent short circuits during penetration. This local differentiation allows both electrical connection and short circuit prevention to coexist.
Solution Approach 2:
The insulating layer is constructed as a composite material combining polymer matrix with metal-filled pores in the first region. This composite structure provides both the insulating properties of the polymer and the conductive pathways through the metal-filled pores, enabling simultaneous electrical connectivity and short circuit prevention.
3Reliability
If a separate substrate tab is used to electrically connect metal layers, then assembly complexity increases and device size increases, but electrical connectivity is ensured
Solution Approach 1:
The patent merges the insulating layer and the electrical connection function into a single integrated structure. The first region of the insulating layer contains metal that fills the pore structure, combining the insulating function with the electrical connection function, thereby eliminating the need for a separate substrate tab and reducing assembly complexity.
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 solution ensures reliable electrical connectivity and prevents short circuits, thermal runaway, and explosions by using an insulating layer with interconnected pores to facilitate direct welding of metal layers, enhancing safety and assembly efficiency.
Implementation Method 1
a third metal that substantially fills the interconnected pore structure within the insulating layer
Implementation Method 2
The insulating layer has an interconnected pore structure
Data Source
AI summary
Examples of the disclosure include an electrode substrate for a rechargeable lithium battery, an electrode and a rechargeable lithium battery including the electrode substrate, and a method for manufacturing the electrode. The electrode substrate for a rechargeable lithium battery includes a first metal layer including a first metal; an insulating layer on the first metal layer and including a polymer; and a second metal layer on the insulating layer and including a second metal. The insulating layer has an interconnected pore structure and is divided into a first region and a second region, and the first region further includes a third metal that substantially fills the interconnected pore structure within the insulating layer.