Integrated Wound Battery Structure for Higher Energy Density
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Solution Overview
Problem
Existing wound batteries face challenges in achieving higher energy density within a limited volume due to their large thickness and complex layering structure, which complicates alignment and increases the risk of safety issues.
Innovation Solution
A wound battery with an integrated current collector structure is developed, combining positive and negative current collectors with insulating layers, and coated with active materials, using a single separator to prevent direct contact and simplify the winding process, resulting in a thinner, more compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a traditional wound battery structure with separate positive and negative electrode sheets is used, then the battery can be assembled, but the thickness becomes large and energy density is limited
Solution Approach 1:
The patent combines the positive current collector and negative current collector into a single integrated current collector structure. The insulating layer is formed on the positive current collector, and the negative current collector is disposed on the insulating layer, creating a unified structure that reduces overall battery thickness while maintaining electrical isolation between positive and negative electrodes.
Solution Approach 2:
The patent transitions from a traditional planar stacking arrangement to a multi-layer integrated structure where the negative current collector is disposed on the insulating layer in a different spatial dimension. This dimensional reorganization allows for more compact packaging and reduced thickness without compromising the functional separation of electrodes.
2Reliability
If separate positive and negative electrode sheets are used with multiple separators, then electrode isolation is achieved, but alignment complexity increases and manufacturing precision requirements rise
Solution Approach 1:
The patent merges the functions of multiple separators into a single integrated insulating layer that is formed directly on the positive current collector. This insulating layer serves both as electrical isolation and as a structural support for the negative current collector, thereby reducing the number of separate components and simplifying alignment requirements.
Solution Approach 2:
The insulating layer is formed on the positive current collector before the negative current collector is disposed on it. This preliminary formation of the insulating layer ensures proper electrical isolation is established in advance, simplifying subsequent assembly steps and reducing alignment complexity during manufacturing.
3Ease of manufacture
If traditional electrode structures are used, then standard manufacturing processes can be applied, but the risk of short circuits increases and safety is compromised
Solution Approach 1:
The patent employs a composite structure consisting of the positive current collector, insulating layer, and negative current collector integrated into a single unit. This composite structure inherently provides electrical isolation between positive and negative electrodes while maintaining manufacturability through a unified construction approach that reduces short circuit risks.
Solution Approach 2:
The insulating layer acts as an intermediary between the positive and negative current collectors, providing electrical isolation and preventing direct contact that could lead to short circuits. This intermediary layer is integrated into the current collector structure, maintaining ease of manufacture while enhancing safety.
Data Source
AI summary
A wound battery which relates to the field of batteries. The wound battery is formed by winding a battery sheet. The battery sheet is flexible and includes a flexible current collector, a positive active layer, a negative active layer, and an insulating separator which is formed on a surface of the positive active layer and/or a surface of the negative active layer, and is configured to prevent the positive active layer from directly contacting the negative active layer.