Swelling Tape Fills Battery Gaps via Electrolyte Expansion
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Solution Overview
Problem
The challenge is to effectively fill gaps between objects, such as an electrode assembly and its encasing can in batteries, to prevent movement and degradation due to external vibrations or impacts, which existing solutions fail to address adequately.
Innovation Solution
A swelling tape is developed, comprising a substrate layer that expands in the length direction upon contact with a fluid, such as a liquid electrolyte, and a pressure-sensitive adhesive layer, allowing the tape to form a three-dimensional shape that securely fixes the objects together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid filler material is used to fill the gap, then the gap filling effectiveness is improved, but the adaptability to different gap sizes and shapes deteriorates
Solution Approach 1:
The filler material transitions from a static rigid state to a dynamic swappable state. The filler can change its shape and volume in response to environmental conditions (temperature, humidity), allowing it to adapt to various gap configurations while maintaining reliable filling performance
Solution Approach 2:
The physical parameters of the filler material (shape, volume, density) are changed to match different gap requirements. By controlling the swelling or shrinking properties of the filler, the system achieves both reliable gap filling and adaptability to different gap sizes
2Manufacturing precision
If a custom-made filler is used for each specific gap, then the gap filling precision is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The filler is designed as a modular component that can be standardized and then adapted to specific applications. Rather than creating entirely custom fillers for each gap, the system uses segmented or modular filler units that can be combined or adjusted to achieve precise fitting while reducing overall manufacturing complexity
Solution Approach 2:
The filler material possesses self-adjusting properties that allow it to automatically conform to the gap geometry without requiring complex custom manufacturing processes. The material's inherent swelling, shrinking, or deformable characteristics enable it to self-fit into various gap configurations, achieving precision while simplifying production
3Adaptability or versatility
If a deformable filler material is used, then the adaptability to different gap shapes is improved, but the structural stability deteriorates
Solution Approach 1:
The filler material exhibits different properties in different regions or under different conditions. It may be soft and deformable in contact with the gap surfaces for adaptation, while maintaining internal structural integrity and stability. This local differentiation of material properties allows simultaneous adaptability and structural stability
Solution Approach 2:
The filler is constructed as a composite material combining deformable components for adaptation with stabilizing components for structural integrity. This composite structure enables the filler to both conform to various gap shapes and maintain sufficient structural stability to perform its filling function effectively
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 swelling tape effectively fills gaps and prevents movement of the electrode assembly within the battery can, enhancing battery performance by maintaining structural integrity and stability.
Implementation Method 1
the substrate layer may be deformed in a length direction upon contact with a fluid such as a liquid
Implementation Method 2
the substrate layer may be, for example, a substrate layer which expands in a length direction upon contact with a fluid such as a liquid
Implementation Method 3
a pressure-sensitive adhesive layer formed on one surface of the substrate layer
Data Source
AI summary
The present application relates to a swelling tape and a method of filling a gap. The swelling tape is, for example, applied in gaps in which a fluid is present and deformed into a three-dimensional shape to fill the gaps and fix in place objects separated by gaps as needed.