Insulated Positive Electrode Plate Layout for Battery Coverage

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Solution Overview

Problem

Lithium-ion batteries suffer from poor coverage of positive and negative electrode plates during manufacturing, leading to insufficient dynamic performance, self-discharge, and safety issues such as thermal runaway and potential fires due to Li dendrite formation and separator piercing.

Innovation Solution

Designing positive electrode plates with a current collector, active material layer, and insulation layers to match the width of negative electrode plates, eliminating the need for a separator and ensuring proper coverage through electrostatic spinning of skeleton-type materials like hydroxyapatite and ceramics to enhance insulation and electrolyte infiltration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the positive electrode plate is made narrower than the negative electrode plate to accommodate Li sources, then Li source distribution is improved, but coverage of the electrode plates becomes poor leading to manufacturing defects

Engineering Contradiction:

ImproveLi source distributionVSAvoidcoverage of electrode plates

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent applies asymmetry by making the positive electrode plate narrower than the negative electrode plate. This asymmetric design allows the positive electrode to have sufficient Li sources while the negative electrode extends beyond to ensure complete coverage during winding, preventing both edge exposure and spiral defects

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent solves the coverage problem by transitioning from a two-dimensional width comparison to a three-dimensional winding structure. The narrower positive electrode plate is wound within the boundaries of the wider negative electrode plate, creating a layered configuration where the negative electrode provides outer coverage protection

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Quantity of substance

If the positive electrode plate is made narrower than the negative electrode plate, then Li source sufficiency is improved, but the risk of Li dendrite formation and separator piercing increases

Engineering Contradiction:

ImproveLi source sufficiencyVSAvoidLi dendrite formation and separator piercing

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The asymmetric width design ensures that the positive electrode plate is narrower than the negative electrode plate, creating sufficient Li sources while the extending negative electrode provides a protective buffer zone that prevents Li dendrite penetration and separator piercing

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent implements beforehand cushioning by designing the negative electrode plate to extend beyond the positive electrode plate boundaries. This extra coverage acts as a cushioning layer that prevents harmful factors like Li dendrites from piercing through the separator and causing short circuits

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Quantity of substance

If electrode plates have different widths, then Li source distribution is optimized, but the battery yields decrease due to excessive height and poor coverage defects

Engineering Contradiction:

ImproveLi source distributionVSAvoidbattery yield

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The patent applies asymmetry by designing the positive electrode plate to be narrower than the negative electrode plate, optimizing Li source distribution while the wider negative electrode ensures complete coverage during winding, eliminating defects that would cause scrap and improving battery yield

Inventive Principle:

Principle #4Asymmetry

4Manufacturing precision

If the positive electrode plate covers the entire negative electrode plate, then coverage is improved, but Li sources become insufficient in certain portions

Engineering Contradiction:

Improvecoverage of electrode platesVSAvoidLi source distribution

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The patent reverses the conventional approach by making the positive electrode plate narrower than the negative electrode plate. This asymmetric design ensures that the positive electrode has sufficient Li sources while the negative electrode extends beyond to provide complete coverage, solving both problems simultaneously

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS20250023195A1Positive electrode plate, battery cell, and battery

Publication Date: 2025.01.16 ZHUHAI COSMX BATTERY CO LTD

AI summary

Disclosed are a positive electrode plate, a battery cell, and a battery. The positive electrode plate includes a current collector, an active material layer, a first and a second insulation layer, where the current collector includes a first and a second surface disposed opposite each other; first surface includes a first, a second, and a third region along a short side; and second surface includes a fourth, a fifth, and a sixth region along a short side; active material layer is disposed in second and fifth region; first insulation layer is disposed in the first, third, fourth, and sixth region; and second insulation layer is disposed on active material layer and first insulation layer. The positive and negative electrode plate have a same width, to resolve a problem of poor coverage of a positive electrode and a negative electrode, thereby greatly improving safety of a battery.