Stepped Electrode Assembly for Curved Battery Capacity
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Solution Overview
Problem
Conventional pouch-shaped battery cells with a rectangular parallelepiped structure do not efficiently utilize curved device spaces, leading to reduced capacity per unit volume due to dead spaces, which limits their integration in devices with curved designs.
Innovation Solution
An electrode assembly with a stepped structure is developed, featuring electrode plates of varying sizes with a thickness difference of 0 to 79 μm, an N/P ratio of 1.0 to 1.1, and a separator plate or sheet to ensure uniform electrolyte impregnation and improved lithium ion transfer, allowing for curvature adaptation and enhanced safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rectangular parallelepiped structure is used for pouch-shaped battery cells, then manufacturing simplicity and structural stability are maintained, but device capacity per unit volume decreases due to dead spaces in curved device areas
Solution Approach 1:
The electrode assembly is divided into multiple electrode plates with different sizes, creating a stepped structure that segments the battery cell volume. This segmentation allows the battery to adapt to curved device spaces more effectively, reducing dead spaces and increasing the quantity of active material that can be packed into the same external volume.
Solution Approach 2:
The invention transitions from a conventional single-plane stacked structure to a multi-level stepped structure by varying the sizes of electrode plates in the stacking direction. This dimensional change creates vertical tiers that better utilize three-dimensional space, particularly in curved device configurations, thereby increasing device capacity per unit volume.
2Quantity of substance
If electrode plates of varying sizes are stacked to create a stepped structure, then device capacity per unit volume increases by utilizing dead spaces, but manufacturing complexity increases
Solution Approach 1:
The stepped structure implements local quality by having different electrode plates at different positions with varying sizes. Each local region of the electrode assembly has optimized dimensions suited to the specific device space requirements, allowing better space utilization without requiring complete redesign of the entire assembly.
Solution Approach 2:
The invention changes the size parameters of electrode plates systematically to create the stepped structure. By controlling the thickness difference between adjacent electrode plates within a specific range (0 to 79 μm), the design achieves space optimization while maintaining manufacturability and structural integrity.
3Manufacturing precision
If the thickness difference between adjacent electrode plates is kept within 0 to 79 μm, then uniform electrolyte impregnation is achieved, but the range of possible size variations is limited
Solution Approach 1:
The invention establishes a specific parameter range for thickness differences (0 to 79 μm) that optimizes electrolyte impregnation uniformity. This controlled parameter change ensures that the stepped structure maintains adequate electrolyte distribution while still providing sufficient size variation to create meaningful space utilization improvements in curved device configurations.
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 stepped electrode assembly increases device capacity per unit volume by utilizing dead spaces and provides improved safety and efficiency in lithium secondary batteries for devices with curved designs.
Implementation Method 1
a separator plate disposed between the electrode plates and/or a one-unit separation sheet disposed between the electrode plates
Implementation Method 2
improved lithium ion transfer
Data Source
AI summary
Disclosed herein is an electrode assembly including two or more electrode plates, each of which has electrode tabs, and a separator plate disposed between the electrode plates and/or a one-unit separation sheet disposed between the electrode plates to cover side surfaces of the electrode plates, which constitute an electrode tab non-formation region, wherein the electrode plates are stacked in a height direction on the basis of a plane such that the electrode plates having opposite polarities face each other in a state in which the separator plate and/or the separation sheet is disposed between the electrode plates, a stack constituted by the electrode plates includes electrode plates having different sizes, and an absolute value of the difference in thickness between the electrode plates having different sizes facing each other is 0 to 79 μm.