Battery Separator Edge Protrusions for Electrode Alignment

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Solution Overview

Problem

Misalignment of electrodes in cylindrical rechargeable batteries during the stacking process can lead to short circuits due to slipping, which is not effectively addressed by existing technologies.

Innovation Solution

A separator with protruding portions on either side, supporting the edges of the electrodes, prevents misalignment by maintaining their position during stacking and winding, thereby reducing the risk of short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If electrodes are stacked repeatedly during manufacturing, then battery production can be achieved, but misalignment and slipping occur causing short circuits

Engineering Contradiction:

Improvebattery production efficiencyVSAvoidelectrode alignment accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The separator acts as an intermediary component between the first and second electrodes. By forming protruding portions on the separator, it provides a mechanical interface that prevents direct contact between electrodes while maintaining alignment, thus avoiding short circuits during the stacking process

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protruding portions are formed on the separator before the electrodes are stacked. This preliminary structural preparation creates predetermined positioning features that guide electrode placement and prevent misalignment during the stacking process

Inventive Principle:

Principle #10Preliminary action

2Loss of substance

If separator width is reduced to match electrode width, then material usage is optimized, but electrode edges are not supported causing misalignment

Engineering Contradiction:

Improveseparator material usageVSAvoidelectrode positioning accuracy

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The separator is segmented into a base portion and protruding portions. The base portion has a width matching the electrode width for optimized material usage, while the protruding portions extend beyond the electrode edges to provide support and positioning without requiring the entire separator to be wider than the electrodes

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP4636885A1Separator for rechargeable battery and electrode assembly including the same

Publication Date: 2025.10.22 SAMSUNG SDI CO LTD

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AI summary

A separator for a rechargeable battery includes a base, a first side protruding portion formed in a first side of the base and protruding in a first direction, and a second side protruding portion formed in a second side of the base and protruding in a second direction. The first side of the base and the second side of the base are opposite to each other, and the first direction and the second direction are opposite to each other with respect to the base.