Wrapped Electrode Stack Assembly for Separator-Safe Alignment

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Solution Overview

Problem

Conventional electrode assemblies face issues with separator deformation, alignment disruption, and short circuits due to weak adhesive forces between stacked unit cells, leading to increased manufacturing costs and time.

Innovation Solution

An electrode assembly with a wrapping film that surrounds and is fused to a stack of electrodes and separators, using a material like polyethylene terephthalate (PET) and ethylene vinyl acetate (EVA), to firmly fix the electrodes and separators in alignment, preventing deformation and short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a tape is attached to fix unit cells, then the alignment of stacked unit cells is improved, but the separator is partially bent causing damage or short circuit

Engineering Contradiction:

Improvealignment of stacked unit cellsVSAvoidseparator deformation and damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent uses a wrapping film made of flexible material that surrounds the entire stack of unit cells instead of rigid tapes. This flexible film conforms to the stack shape and fixes unit cells through adhesion to the outer surface, avoiding mechanical contact and bending forces on the separator while maintaining alignment.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent extracts the fixation function from the traditional tape method and relocates it to a wrapping film that operates on the outer surface of the stack. This separates the alignment function from the separator, eliminating the harmful interaction between fixation elements and the separator.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If a tape is used to fix unit cells, then alignment is improved, but the tape easily separates during electrolyte injection or degassing process

Engineering Contradiction:

Improvealignment of stacked unit cellsVSAvoidadhesive strength during electrolyte injection

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The wrapping film provides continuous coverage around the stack, distributing mechanical stresses uniformly during electrolyte injection and degassing. This flexible structure accommodates volume changes without creating stress concentration points that would cause separation.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent combines multiple functions into the wrapping film: structural support, alignment maintenance, and stress distribution during electrolyte injection. This integrated approach replaces the single-function tape with a multi-functional film that addresses both alignment and reliability concerns.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If adhesive is applied to unit cells for bonding, then the alignment is improved, but manufacturing costs and manufacturing time increase

Engineering Contradiction:

Improvealignment of stacked unit cellsVSAvoidmanufacturing time and cost

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent extracts the alignment function from the adhesive bonding process and implements it through external wrapping. This eliminates the need for precise adhesive application and alignment procedures, simplifying the manufacturing process and reducing costs.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The wrapping film provides a simple, cost-effective solution for maintaining alignment without requiring complex adhesive application equipment or multi-step bonding processes. The film can be applied in a single operation, significantly reducing manufacturing time.

Inventive Principle:

Principle #30Flexible shells and thin films

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 wrapping film effectively fixes electrodes and separators in alignment, preventing deformation and short circuits, reduces manufacturing costs, and enhances energy density by reducing the thickness of the assembly.

Implementation Method 1

a wrapping film 200 that surrounds the stack 100 and is fused to the stack 100 to fix the plurality of electrodes 110 and the plurality of separators 120

Methodology Applied

Scientific EffectThermal bonding:

Data Source

PatentUS20250329880A1Electrode Assembly And Manufacturing Method Thereof

Publication Date: 2025.10.23 LG ENERGY SOLUTION LTD

AI summary

An electrode assembly including a stack formed by aligning and alternately stacking a plurality of electrodes and a plurality of separators in a first direction, and a wrapping film surrounding and fused to the stack to fix the plurality of electrodes and the plurality of separators is provided. Electrode tabs of the plurality of electrodes are disposed at one side or the other side of the stack in a second direction intersecting with the first direction. The wrapping film surrounds both of the stack in the first direction and both sides of the stack in a third direction intersecting the first direction and the second direction. The wrapping film is fused to at least one of the sides in the first direction.