Porous Polymer Electrode Assembly for Secondary Battery Manufacturing
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Solution Overview
Problem
Conventional secondary battery electrode assemblies require complex processes for manufacturing, involving separate coating and assembly of positive and negative electrode plates with a separator, which increases time and complexity.
Innovation Solution
An electrode assembly is created by coating positive and negative electrode active materials on opposite surfaces of a porous polymer layer with conductive layers, which is then folded in a zigzag shape, simplifying the manufacturing process and eliminating the need for separate electrode collectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate positive and negative electrode plates are manufactured and assembled using conventional jelly-roll or stack-type methods, then electrode functionality is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent combines the positive electrode collector, negative electrode collector, and separator into a single integrated porous polymer layer. The porous polymer layer simultaneously serves as the separator and as the substrate for coating both positive and negative electrode active materials, eliminating the need for separate electrode plates and reducing manufacturing steps.
Solution Approach 2:
The porous polymer layer performs multiple functions: it acts as the separator to prevent direct contact between electrodes, serves as the collector for both positive and negative electrodes, and provides the structural framework for the electrode assembly. This multi-functionality reduces the number of components and simplifies the overall structure.
2Productivity
If conventional separate coating and assembly processes are used for electrode plates, then proper electrode formation is achieved, but manufacturing time increases
Solution Approach 1:
The porous polymer layer is prepared in advance with its porous structure and conductivity established before the electrode active materials are coated. This preliminary preparation allows for rapid coating of both positive and negative electrodes without requiring separate plate formation and assembly steps, significantly reducing manufacturing cycle time.
Solution Approach 2:
The manufacturing process continues without interruption by coating both positive and negative electrode active materials on the porous polymer layer in sequence, then folding the layer to complete the electrode assembly in a single continuous operation. This eliminates idle time between separate coating and assembly processes.
3Ease of manufacture
If a single porous polymer layer serves as both separator and electrode collector, then manufacturing is simplified, but ensuring proper conductivity and separation becomes more difficult
Solution Approach 1:
The porous polymer layer has different properties in different regions: the bulk material provides insulation and separation, while the coated electrode active materials provide conductivity where needed. The coating process is controlled to ensure uniform distribution of active materials on the porous surface, achieving both separation and conductivity functions in different locations of the same structure.
Solution Approach 2:
The electrode assembly uses a composite structure where the porous polymer layer (insulating material) is combined with coated electrode active materials (conductive materials). This composite approach allows the single layer to simultaneously provide both insulating and conducting properties in different regions, resolving the contradiction between simplification and precision.
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 approach reduces manufacturing time and complexity, enabling the simultaneous coating and assembly of electrode materials while preventing short circuits, thus improving productivity and efficiency in producing high-power secondary batteries.
Implementation Method 1
a conductive layer on each of the first and second surfaces of the porous polymer layer
Implementation Method 2
an active material layer on each of the first and second surfaces of the porous polymer layer
Implementation Method 3
folding the coated porous polymer layer in a zigzag shape to form the electrode assembly
Implementation Method 4
a porous polymer layer having first and second surfaces opposite each other
Data Source
AI summary
An electrode assembly includes a porous polymer layer, a conductive layer on each of a first and a second surface of the porous polymer layer, and an active material layer on each of the first and second surfaces of the porous polymer layer.