Battery Separator Extension Wave Glue Bonding
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Solution Overview
Problem
Secondary batteries are prone to short-circuiting due to external forces like drops, which affects their performance and safety.
Innovation Solution
An electrode assembly with a separator extension portion connected by a glue layer, featuring bonding portions in a wave structure configuration that increases restriction points and bonding strength, thereby preventing separator shrinkage and reducing the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the separator extension portion is left unbonded, then the structure remains simple and easy to manufacture, but the separator may shrink under external forces causing short circuits
Solution Approach 1:
The separator extension portion is divided into multiple bonding portions (first bonding portion, second bonding portion, third bonding portion) with different orientations. This segmentation allows the glue layer to bond the separator at multiple discrete locations and angles, preventing shrinkage in different directions while maintaining manufacturing feasibility through modular bonding application.
Solution Approach 2:
The bonding portions are arranged in three-dimensional space with different orientations (first bonding portion extending in width direction, second bonding portion extending in length direction, third bonding portion at an angle). This multi-dimensional arrangement creates a network of restriction points that effectively prevents separator shrinkage from all directions, transforming a simple linear bonding approach into a spatial bonding system.
2Reliability
If multiple bonding portions are added to the glue layer, then the separator restriction effectiveness increases, but the manufacturing process becomes more complex
Solution Approach 1:
The glue layer is segmented into multiple bonding portions that can be applied in a systematic manner. The first bonding portion extends in the width direction, the second in the length direction, and the third at an angle between them. This segmentation allows manufacturers to apply glue in discrete stages or patterns, making the process more manageable despite the increased number of bonding locations.
Solution Approach 2:
Different bonding portions are strategically positioned at specific locations and orientations based on the local shrinkage risks of the separator extension portion. The first bonding portion addresses width-direction shrinkage, the second addresses length-direction shrinkage, and the third addresses diagonal shrinkage. This localized bonding approach ensures that glue is applied only where needed, optimizing manufacturing efficiency.
3Strength
If the bonding portions are arranged in a wave structure, then the bonding strength and restriction points increase, but the manufacturing precision requirements increase
Solution Approach 1:
The bonding portions are arranged in a wave structure pattern rather than straight lines. This curved, undulating arrangement creates multiple peaks and valleys that serve as natural restriction points for the separator extension portion. The wave structure distributes bonding stress more evenly and provides geometric interlocking that enhances bonding strength while the repetitive wave pattern simplifies manufacturing by using a standardized geometric motif.
Solution Approach 2:
The wave structure introduces a spatial dimension to the bonding arrangement, creating a three-dimensional bonding network from the two-dimensional separator surface. The wave peaks and valleys create multiple bonding zones at different heights and positions, increasing the effective bonding area and restriction points without requiring extremely precise single-point bonding.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The wave structure glue layer effectively bonds the separator extension portions, enhancing the safety of the battery by preventing shrinkage and reducing the risk of short circuits, thus improving the overall performance and reliability of the battery.
Implementation Method 1
The extension portion is provided with a glue layer including a first bonding portion extending in a width direction of the electrode assembly. The first bonding portion is parallel to the width direction.
Data Source
AI summary
An electrode assembly including a first electrode plate, a second electrode plate and a separator between the first electrode plate and the second electrode plate. The separator includes an extension portion extending to the outside of the first electrode plate and the second electrode plate in a length direction of the electrode assembly. The extension portion is provided with a glue layer including a first bonding portion extending in a width direction of the electrode assembly. The first bonding portion is parallel to the width direction.