Spiral-Wound Electrochemical Bundle With Nested U-Shaped Electrodes

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Solution Overview

Problem

Existing electrochemical elements face reduced energy density due to oversizing of one electrode, which compromises electrical isolation and increases the risk of short circuits.

Innovation Solution

The electrodes are designed with a U-shaped profile, with active parts extending into each other's intermediate spaces, separated by a separator, enhancing electrical isolation without oversizing, thus increasing energy density and reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If one electrode is oversized relative to the other, then electrical isolation between electrodes is improved, but energy density of the electrochemical element deteriorates

Engineering Contradiction:

Improveelectrical isolationVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The electrodes are divided into multiple discrete active parts (first and second electrochemically active parts) separated by intermediate spaces. The separator is segmented to extend into these intermediate spaces, creating multiple isolation zones. This segmentation allows electrical isolation without requiring overall electrode size mismatch, as each segment is independently isolated.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator is nested into the intermediate spaces between the electrochemically active parts of the electrodes. This nesting arrangement allows the separator to occupy the available space efficiently, providing electrical isolation within the compact structure without requiring additional oversizing of one electrode relative to the other.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If one electrode is oversized relative to the other, then electrical isolation between electrodes is improved, but the risk of short circuits increases

Engineering Contradiction:

Improveelectrical isolationVSAvoidshort circuit risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The separator acts as an intermediary element that is strategically positioned within the intermediate spaces of the electrodes. This intermediary structure provides electrical isolation between the positive and negative electrodes, preventing direct contact and reducing short circuit risk without requiring asymmetric electrode sizing.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Quantity of substance

If electrode material is reduced to match sizes, then energy density is improved, but electrical isolation between electrodes deteriorates

Engineering Contradiction:

Improveenergy densityVSAvoidelectrical isolation

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The separator is positioned specifically within the intermediate spaces between the electrochemically active parts, providing localized electrical isolation where it is most needed. This local quality approach allows the electrodes to be sized optimally for energy density while maintaining adequate isolation through targeted separator placement rather than overall electrode dimensioning.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP4645489A1Electrochemical element comprising a spirally wound electrochemical bundle and associated manufacturing method

Publication Date: 2025.11.05 SAFT GRP SA

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AI summary

The electrochemical element (10) comprises an electrochemical bundle consisting of a flat assembly (22) spirally wound around a central axis (A-A') and comprising: - a negative electrode (30); - a positive electrode (60); and - a separator (90). The negative electrode (30) has a U-shaped profile and delimits an intermediate space (38) of the negative electrode (30). The positive electrode (60) has a U-shaped profile and delimits an intermediate space (68) of the positive electrode (60). A first electrochemically active portion (64) of the positive electrode (60) extends into the intermediate space (38) of the negative electrode (30), and a second electrochemically active portion (36) of the negative electrode (30) extends into the intermediate space (68) of the positive electrode (60).