Step-Formed Electrode Assembly for Battery Design Flexibility
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrode assemblies in lithium secondary batteries have limited design flexibility and require complex processes for manufacturing, making it difficult to produce batteries with various forms to match the diverse shapes of modern mobile devices, while also restricting the degree of freedom in shape and increasing dead space, which affects battery capacity and performance.
Innovation Solution
An electrode assembly is developed using a stacked and folded scheme with at least two rectangularly shaped separation films, allowing for the alternation of cathode and anode units with different sizes and shapes, forming steps and interfaces that enhance electrochemical reactions and simplify the manufacturing process by eliminating the need for individual unit cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If unit cells having the same size are stacked to form an electrode assembly, then manufacturing process is simplified, but design flexibility and shape variety are considerably reduced
Solution Approach 1:
The electrode assembly is divided into multiple electrode units with different sizes (first electrode unit, second electrode unit, third electrode unit) that can be stacked in sequence. This segmentation allows each unit to have optimized dimensions for specific device requirements while maintaining a systematic manufacturing approach through standardized stacking procedures.
Solution Approach 2:
Different electrode units are designed with different areas and dimensions to match local requirements of the battery application. The first electrode unit has a larger area, while subsequent units have progressively smaller areas, allowing the battery to adapt to irregular device spaces and maximize space utilization without requiring complete redesign of the manufacturing process.
2Adaptability or versatility
If individual electrodes are stacked to alter design, then design flexibility is improved, but manufacturing process becomes complicated and difficult
Solution Approach 1:
The battery is divided into standardized electrode units that can be stacked in different configurations. This segmentation provides design flexibility through various stacking arrangements while maintaining manufacturing simplicity through standardized unit designs and assembly procedures.
Solution Approach 2:
Electrode units are stacked in a nested configuration where smaller units (second and third electrode units) are positioned on top of larger units (first electrode unit). This nesting approach allows for compact, space-efficient designs that adapt to device contours while following a systematic stacking manufacturing process.
3Ease of manufacture
If electrode assembly uses uniform unit cells, then manufacturing is easier, but dead space increases and battery capacity is reduced
Solution Approach 1:
Electrode units with different areas are used to match the local space requirements within the battery housing. The first electrode unit has a larger area to maximize capacity in the base region, while smaller second and third electrode units fill upper regions, eliminating dead space and increasing overall active material quantity without complicating manufacturing.
4Ease of manufacture
If electrode assembly has fixed shape, then manufacturing process is simplified, but ability to match diverse device shapes is limited
Solution Approach 1:
The electrode assembly is segmented into multiple stackable units that can be arranged in different vertical configurations. This allows the overall battery shape to adapt to diverse device contours while each individual unit maintains a standardized, easy-to-manufacture structure.
Solution Approach 2:
The battery design utilizes the vertical stacking dimension to achieve shape adaptability. By stacking electrode units of different sizes in the vertical direction, the battery can conform to various device shapes and spaces without requiring complex lateral modifications to the manufacturing process.
Data Source
AI summary
There is provide an electrode assembly including an electrode laminate having a plurality of electrode units rolled up to be stacked on one another in at least two rectangularly shaped separation films, the electrode assembly being characterized in that at least one of two rectangularly shaped separation films is disposed on upper and lower surfaces of the respective electrode unit, at least one separation film disposed on one surface being different from a separation film disposed on another surface, and the electrode laminate includes at least one step formed by stacking an electrode unit having a difference in area from an electrode unit adjacent thereto, having one of the rectangularly shaped separation films as a boundary therebetween.