Stair-like Hybrid Electrode Assembly for Space-Constrained Battery Design
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Solution Overview
Problem
Existing battery cell designs face challenges in maximizing internal device space utilization and accommodating various device shapes, particularly in slim designs, due to fixed electrode assembly sizes and complex electrical connections.
Innovation Solution
A hybrid electrode assembly with unit cells of different sizes, stacked vertically and wound with a separation film, forming a stair-like structure to increase capacity and adapt to diverse device shapes, while maintaining safety through balanced positive and negative electrode ratios and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrode assemblies have the same size or capacity, then manufacturing consistency is maintained, but device space utilization is reduced and design flexibility is limited
Solution Approach 1:
The electrode assembly is divided into multiple unit cells with different capacities (first, second, and third unit cells). These segmented unit cells can be independently configured to match different device space requirements, resolving the contradiction between maintaining manufacturing consistency and achieving design flexibility.
Solution Approach 2:
Different unit cells are assigned different capacities and positions within the electrode assembly. The first unit cell has a larger capacity and is positioned to utilize maximum space, while smaller unit cells fill remaining gaps. This local differentiation allows the overall assembly to adapt to various device shapes without requiring complete redesign.
2Adaptability or versatility
If battery cell capacity is reduced to fit novel device structures, then device integration is improved, but energy density decreases
Solution Approach 1:
Unit cells of different sizes are nested within each other in a stair-like configuration. The smaller second and third unit cells are positioned within the spatial envelope defined by the larger first unit cell, allowing maximum utilization of available device space without reducing the capacity of individual unit cells.
Solution Approach 2:
The electrode assembly transitions from a two-dimensional planar layout to a three-dimensional stair-like structure by stacking unit cells at different heights and positions. This dimensional transformation allows the battery to occupy vertical and lateral spaces simultaneously, increasing total capacity while adapting to novel device structures.
3Adaptability or versatility
If electrode assembly design is modified for various device shapes, then design flexibility is improved, but manufacturing complexity increases
Solution Approach 1:
The electrode assembly design with multiple configurable unit cells serves multiple functions: it can be configured for different device shapes, maintains consistent manufacturing processes for each unit cell type, and provides scalable capacity options. This universal design approach allows the same basic unit cell structures to be reused across different device applications.
Solution Approach 2:
The electrode assembly is pre-configured with multiple unit cells of different capacities during manufacturing, allowing the final device integrator to simply select and arrange the appropriate unit cells for their specific space requirements. This preliminary preparation of modular units simplifies the overall manufacturing ecosystem.
Data Source
AI summary
Disclosed herein is an electrode assembly including unit cells, each of which is constituted by an electrode plate stack configured to have a structure in which a separator is disposed between electrode plates comprising positive electrodes or negative electrodes, wherein the electrode assembly includes a combination of two or more kinds of unit cells having different sizes, the unit cells are stacked in a height direction on the basis of a plane, two or more of the unit cells located at a lower part of the electrode assembly, i.e. two or more base unit cells, are wound using a single sheet-type separation film to constitute an integrated base structure, and the others of the unit cells excluding the base unit cells, i.e. sub unit cells, are stacked in a state in which a separator is disposed between the respective sub unit cells.