Recessed Current Collector Electrode for Lithium Battery

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Solution Overview

Problem

Conventional electrodes for lithium secondary batteries are difficult to manufacture smoothly and uniformly, leading to damage during the manufacturing process and storage, particularly at the lateral surfaces and edge portions.

Innovation Solution

An electrode design featuring a metallic current collector with recessed areas for embedding the electrode mixture, where the mixture is surrounded by the current collector, and a pattern can be formed on the surface to prevent separation and damage, with a method involving molding and embedding the mixture in the recessed areas to control thickness and shape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If electrode slurry is applied onto the top surface of a planar current collector and pressurized/dried to manufacture an electrode, then the electrode can be formed with electrode active material layer, but the electrode active material is separated during pressurization and the electrode is damaged during storage, particularly at lateral surfaces and edge portions

Engineering Contradiction:

Improveease of electrode manufacturingVSAvoidelectrode integrity during storage

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The current collector is segmented into a recessed portion and edge portions, creating a structured configuration where the recessed portion holds the electrode active material layer. This segmentation prevents the electrode from being a flat, vulnerable structure by dividing it into functional zones that reduce stress concentration and material separation during manufacturing and storage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The current collector is transformed from a two-dimensional planar structure to a three-dimensional structure with a recessed portion. This dimensional change creates depth and volume, allowing the electrode active material layer to be contained within the recessed area, which provides structural support and prevents damage at lateral surfaces and edges during storage.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If electrode slurry is applied onto the top surface of a current collector in a semi-solid state, then the electrode can be formed, but the slurry cannot be applied smoothly and uniformly with ease

Engineering Contradiction:

Improvesmoothness of slurry applicationVSAvoiduniformity of electrode active material layer

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The current collector is pre-formed with a recessed portion before the electrode slurry is applied. This preliminary structural preparation creates a defined cavity that guides and contains the slurry application process, ensuring that the semi-solid slurry is distributed uniformly within the recessed area without spilling or creating uneven thickness, thereby improving both ease of application and manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The current collector has different structural qualities in different regions: the recessed portion provides a contained space for uniform slurry distribution, while the edge portions provide structural support. This local differentiation of structure allows the slurry to be applied smoothly in the recessed area while maintaining overall electrode integrity.

Inventive Principle:

Principle #3Local quality

3Reliability

If the electrode is manufactured with a planar shape to form a flat stacking surface, then the electrode can prevent separation from another electrode or separator upon stacking, but the electrode is damaged during storage, particularly at lateral surfaces and edge portions

Engineering Contradiction:

Improveelectrode stability during stackingVSAvoiddamage at lateral surfaces and edge portions

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The current collector is divided into a recessed portion that contacts the electrode active material layer and edge portions that extend outward. This segmentation allows the electrode to maintain a stable stacking surface through the recessed portion while the edge portions are structurally protected, reducing damage at lateral surfaces and edges during storage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The recessed portion of the current collector acts as a cushioning structure that absorbs and distributes stress during stacking and storage. By pre-designing this recessed configuration, the electrode is protected from damage at lateral surfaces and edge portions before damage can occur during subsequent handling and storage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS11094942B2Method for manufacturing an electrode having a metal plate with a recess formed therein, an electrode including the same, and an electrochemical device including the same

Publication Date: 2021.08.17 LG ENERGY SOLUTION LTD

AI summary

The present disclosure relates to an electrode which is manufactured with ease and causes little damage during storage, and a method for manufacturing the same. The electrode includes a metallic current collector and an electrode mixture, wherein the current collector has a recess formed by denting the remaining portions except edge portions having a width, and the electrode mixture is embedded in the recess.