Stacked Electrode Assembly Edge Insulation Against Battery Short Circuits
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Solution Overview
Problem
Lithium secondary batteries face safety risks due to short circuits caused by contact between electrodes, particularly in lithium metal batteries where dendrites form, leading to potential ignition or explosion, and existing insulation methods are inadequate.
Innovation Solution
An electrode assembly with an insulation layer formed on the tab and edge portions of electrodes, larger than the counter electrode, using a combination of insulation films, organic layers, or organic-inorganic mixed layers to prevent short circuits and dendrite growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insulation tape is attached only on tab portion, then manufacturing cost is reduced, but short circuit prevention capability is insufficient
Solution Approach 1:
The patent applies different insulation measures to different locations based on risk assessment. Insulation layers are specifically applied to edge portions and tab portions where short circuits are most likely to occur, rather than uniformly insulating the entire electrode. This localized approach optimizes the balance between safety and manufacturing cost.
Solution Approach 2:
The insulation solution is divided into separate components: insulation layers applied to edge portions and insulation tapes applied to tab portions. This segmentation allows each component to address specific short circuit risks at different locations, improving overall effectiveness while maintaining cost efficiency.
2Reliability
If insulation layer is formed on entire electrode surface, then short circuit prevention is maximized, but manufacturing cost and complexity increase
Solution Approach 1:
Instead of uniform insulation across the entire electrode surface, the patent selectively applies insulation layers only to edge portions and tab portions where short circuit risks are concentrated. This reduces material usage and structural complexity while maintaining adequate protection.
Solution Approach 2:
The patent implements partial insulation coverage focusing on critical areas rather than complete coverage. This partial action approach provides sufficient protection against the most common short circuit modes while avoiding the excessive complexity and cost of full-surface insulation.
Data Source
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AI summary
The present disclosure relates to an electrode assembly having a stack form of an electrode, a separator and a counter electrode, in which each of the electrode and the counter electrode includes a tab extending from a current collector; the electrode is larger than the counter electrode at four sides including a side from which the tap extends thereof, to have an exposed portion; and an insulation layer is formed on a tab portion of the electrode and on an edge portion of the electrode.