Battery Separator Protrusions for Electrode Alignment in Winding

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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 to support and align electrodes, preventing misalignment and potential short circuits by ensuring proper positioning during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If electrodes are repeatedly stacked during the winding process, then the electrode assembly can be formed, but misalignment occurs due to slipping

Engineering Contradiction:

Improveelectrode assembly formation efficiencyVSAvoidelectrode alignment accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The separator is designed with protruding portions that extend beyond the electrode edges before stacking. These protruding portions act as preliminary positioning features that guide and constrain the electrodes during the stacking process, preventing misalignment from occurring in the first place

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protruding portions of the separator serve as an intermediary element between the electrodes during stacking. They mediate the positioning relationship between electrodes by providing physical contact points that prevent slipping and maintain proper alignment throughout the assembly process

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If misalignment occurs between electrodes, then the battery can still be assembled, but short circuits occur between electrodes of different polarities

Engineering Contradiction:

Improveassembly feasibilityVSAvoidshort circuit prevention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The protruding portions of the separator create preliminary counter-actions that prevent the harmful effect of electrode slipping. By providing mechanical constraint before misalignment can occur, the design preemptively counteracts the slipping tendency that would otherwise lead to short circuits

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The separator's protruding portions provide beforehand cushioning by creating a mechanical barrier that absorbs and prevents the harmful effect of electrode misalignment. This protective feature is built into the separator structure to cushion against positioning errors before they can cause short circuits

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS20250329882A1Separator for rechargeable battery and electrode assembly including the same

Publication Date: 2025.10.23 SAMSUNG SDI CO LTD

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.