Wound Electrode Assembly Layout for Balanced Conductive Layer Forces
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Solution Overview
Problem
The performance of battery assemblies is hindered by the uneven forces applied to the conductive structure during charging/discharging, leading to potential tearing or wrinkling, which affects current flow capacity and safety.
Innovation Solution
An electrode assembly with a conductive layer having a first part coated with an active substance layer and a second part without, spaced apart in a specific ratio to maintain balanced forces, ensuring stable connection and improved structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conductive layer has uniform thickness and continuous coating, then the manufacturing process is simple, but the forces applied during charging/discharging are uneven causing tearing or wrinkling
Solution Approach 1:
The conductive layer is divided into multiple segments (first conductive layer, second conductive layer, third conductive layer) with different thicknesses rather than being a uniform continuous coating. This segmentation allows different regions to handle mechanical stresses differently, preventing tearing and wrinkling while maintaining manufacturing feasibility through a modified coating process that applies varying thicknesses in different regions.
Solution Approach 2:
Different regions of the conductive layer are given different local properties - the first conductive layer has greater thickness than the second conductive layer, which in turn is thicker than the third conductive layer. This local quality variation optimizes each region's ability to withstand specific mechanical forces during battery operation, with thicker regions providing enhanced structural support where needed.
2Volume of moving object
If the conductive layer thickness is reduced to minimize space, then the battery cell size is reduced, but the connection strength and current flow capacity are insufficient
Solution Approach 1:
The conductive layer is segmented into multiple layers with strategically varying thicknesses. The first conductive layer has greater thickness to provide strong connection strength and current flow capacity at critical interfaces, while the second and third conductive layers have reduced thicknesses to minimize overall space consumption. This segmentation allows the conductive structure to maintain necessary mechanical and electrical performance while reducing the total volume occupied by the conductive material.
Solution Approach 2:
The conductive layer exhibits local quality variations where the first conductive layer has greater thickness at regions requiring high connection strength and current flow capacity, while the second and third conductive layers have smaller thicknesses in regions where space minimization is prioritized. This local optimization ensures that thickness is concentrated where most needed for performance while minimizing overall volume.
3Quantity of substance
If the second parts are spaced closely to increase active substance coverage, then the energy density increases, but the structural stability and force balance are compromised
Solution Approach 1:
The electrode assembly is segmented into multiple second parts (first, second, and third conductive layers) with controlled spacing between them. This segmentation allows the active substance coating to be distributed across multiple separated regions rather than requiring continuous close spacing, maintaining structural stability while still achieving high overall active substance coverage through the cumulative effect of multiple segments.
Solution Approach 2:
Different regions of the electrode assembly have different local configurations - the first, second, and third conductive layers are positioned at different locations along the winding direction with specific spacing relationships. This local quality variation allows optimization of both active substance coverage and structural stability, with each region's spacing tailored to balance energy density requirements with mechanical stability needs.
Data Source
AI summary
Provided are an electrode assembly, a method and system for manufacturing the same, a battery cell, a battery, and an electric apparatus. The electrode assembly includes an electrode member wound along a winding direction, the electrode member includes an electrode body, and the electrode body includes an insulating matrix and a conductive layer disposed on the insulating matrix; and the conductive layer includes a first part coated with an active substance layer and a second part coated with no active substance layer; the second part is provided in a quantity of N, and the N second parts are spaced apart in the winding direction; and in the winding direction, distance between the Mth and (M-1)th second parts is L1., and distance between the Mth and (M+1)th second parts is L2, where both N and M are positive integers, 2 ≤ M ≤ N-1, and 0.95 < L2/L1 < 1.05.