Stepped Electrode Assembly for Flexible Battery Design
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Solution Overview
Problem
Existing electrode assemblies are limited in manufacturing batteries with various designs due to their uniform size, making it difficult to accommodate the diverse shapes of modern mobile devices, and complicate manufacturing processes when design changes are required.
Innovation Solution
An electrode assembly with stepped portions formed by unit cells of different sizes and types, such as Z-folded and laminated stacked types, where mutually-facing electrodes have different polarities and areas, allowing for flexible stacking and simpler manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrode assemblies are manufactured by stacking unit cells or electrodes having the same size, then manufacturing process is simplified, but it becomes difficult to manufacture batteries having various designs
Solution Approach 1:
The electrode assembly is divided into multiple electrode units with different sizes, where each unit can be independently configured. This segmentation allows the battery to accommodate various device shapes and designs while maintaining a manageable manufacturing process through modular assembly of standardized units.
Solution Approach 2:
Different regions of the electrode assembly have different electrode unit sizes arranged according to specific patterns (e.g., stepped configurations). This local variation in quality enables the battery to match diverse device form factors while using consistent manufacturing processes for each unit type.
2Adaptability or versatility
If battery designs are changed to accommodate various mobile device shapes, then adaptability to devices is improved, but manufacturing processes become complicated or difficult to perform
Solution Approach 1:
The electrode assembly consists of multiple electrode units that can be arranged in different configurations (such as stepped arrangements with different numbers of units). This segmentation allows design flexibility to match various device shapes while maintaining standardized manufacturing processes for each unit type.
Solution Approach 2:
The electrode assembly structure is made dynamic by allowing different numbers and arrangements of electrode units to be stacked. This enables the same manufacturing process to produce various battery designs by simply changing the stacking configuration rather than redesigning the entire manufacturing process.
3Productivity
If electrode assemblies have uniform size, then manufacturing is easier, but dead space increases and spatial efficiency decreases
Solution Approach 1:
The electrode assembly uses electrode units with different sizes arranged in specific patterns (such as stepped configurations where units decrease in size from bottom to top). This local variation eliminates dead space and improves spatial efficiency while maintaining a systematic configuration that simplifies manufacturing.
Solution Approach 2:
The electrode assembly transitions from a uniform two-dimensional arrangement to a three-dimensional stepped structure with varying unit sizes. This dimensional change allows better space utilization and eliminates dead space while maintaining manufacturing simplicity through standardized unit configurations.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
There is provided an electrode assembly comprising at least one stacked and folded type electrode stack in which a plurality of electrode units having electrode tabs are stacked in a state that the electrode units are separated by a sheet of separating film. The stacked and folded type electrode stack includes at least one stepped portion formed of electrode units having different areas and stacked on one another.