Porous Insulated Electrode Substrate for Tabless Battery Connection
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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, which complicate assembly and increase the risk of short circuits.
Innovation Solution
An electrode substrate design 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, while reducing short circuits through pore filling with metal during welding.
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 to the general substrate tab, then electrical connection between metal layers is achieved, but the length of the general substrate tab increases, making assembly challenging 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 provide electrical connection. This segmentation allows the strip terminal to be directly attached to the electrode substrate without requiring a long general substrate tab, as the metal-filled first region provides the necessary electrical pathway between metal layers.
Solution Approach 2:
The metal is nested within the pore structure of the insulating layer in the first region, creating a compact structure where the electrical connection is embedded within the insulating layer itself. This eliminates the need for an external general substrate tab extending outward from the electrode substrate.
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 design ensures reliable electrical connection of metal layers and prevents short circuits, thermal runaway, and explosions by using a polymer-based insulating layer with controlled porosity, enhancing assembly efficiency and safety.
Implementation Method 1
melting a first metal or a second metal included in a first metal layer or a second metal layer in an area to which a strip terminal is attached to substantially fill interconnected pores in an insulating layer
Implementation Method 2
a third metal that substantially fills the interconnected pore structure within the insulating layer
Data Source
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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.