Electrode Stack Separator Layout for Penetration-Resistant Insulation

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Solution Overview

Problem

Existing secondary batteries face challenges in preventing electrical short circuits and improving insulation within the electrode stack, particularly when subjected to external penetrations such as needle-shaped structures.

Innovation Solution

The electrode stack design incorporates a separator with multiple bent regions and through-holes, ceramic coating regions, and insulating tape to enhance insulation and prevent short circuits, utilizing a Z or S-shaped separator configuration with staggered electrode plates to intersect and improve structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separator with multiple bent regions and through-holes is used, then insulation and structural integrity are improved, but device complexity increases

Engineering Contradiction:

Improveinsulation performanceVSAvoidseparator structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The separator is divided into multiple regions (first separator region, second separator region, third separator region, fourth separator region) with distinct functions. The first and third regions provide baseline insulation, while the second and fourth regions with through-holes and ceramic coatings provide enhanced protection against penetration. This segmentation allows each region to be optimized for its specific role, improving overall reliability without requiring complete redesign of the entire separator.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the separator are given different properties: the second and fourth separator regions contain through-holes filled with insulating material and ceramic coating layers, providing localized enhanced insulation and penetration resistance. The first and third regions maintain standard separator properties. This local quality approach addresses the contradiction by concentrating complexity only where needed for improved reliability.

Inventive Principle:

Principle #3Local quality

2Reliability

If ceramic coating regions with openings are added to the separator, then insulation against penetration is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveshort circuit preventionVSAvoidseparator fabrication

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The ceramic coating is applied to the separator surface in advance, with openings formed through the coating layer. The through-holes in the second and fourth separator regions are filled with insulating material before final assembly. These preliminary actions prepare the separator structure to resist penetration and prevent short circuits before the battery is put into service, addressing reliability concerns while establishing a manufacturable process sequence.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The separator combines multiple materials: the base separator material, ceramic coating material for heat and penetration resistance, and insulating material filling the through-holes. This composite structure provides enhanced short circuit prevention through the synergistic effects of different materials, while the layered fabrication approach maintains ease of manufacture through established coating and assembly processes.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If staggered electrode plates with insulating tape are used, then structural stability is improved, but device complexity increases

Engineering Contradiction:

Improveelectrode stack stabilityVSAvoidelectrode arrangement

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The separator is configured in a Z-shape or S-shape with bent regions instead of a straight line. This curved configuration allows the separator to follow the staggered arrangement of electrode plates, maintaining contact and insulation between all electrodes. The curvature adapts the separator geometry to the electrode stack layout, improving structural stability while the regular Z or S pattern keeps manufacturing complexity manageable.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

Insulating tape is introduced as an intermediary element between adjacent electrode plates in the staggered configuration. This tape provides additional insulation at critical interfaces where electrodes are close together, enhancing structural stability and preventing short circuits. The insulating tape is a simple additive component that addresses the complexity issue by using an off-the-shelf material rather than redesigning the electrode plates themselves.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20260066469A1Secondary battery

Publication Date: 2026.03.05 SAMSUNG SDI CO LTD

AI summary

A secondary battery includes an electrode stack having a separator, the separator including a first separator region, a second separator region, a third separator region, and a fourth separator region, a first negative electrode plate between the first separator region and the second separator region, and a first positive electrode plate between the third separator region and the fourth separator region, an insulating tape on a periphery of the electrode stack, and a case receiving the electrode stack and the insulating tape, wherein one side of the second separator region contacts one side of the third separator region.