Zigzag Electrode Assembly With Localized Heat-Press Bonding
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Solution Overview
Problem
Zigzag-type electrode assemblies experience non-uniform adhesive force distribution due to uneven heat and pressure transmission, leading to electrode separation, reduced stiffness, and safety issues, along with decreased air permeability and increased electrical resistance.
Innovation Solution
A method for manufacturing a zigzag-type electrode assembly involving alternately disposing cathodes and anodes between zigzag-folded separators, followed by uniform heat and pressure application to form unit electrode assemblies, which are then stacked, ensuring consistent bonding throughout the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat and pressure are increased to improve bonding strength, then adhesive force between electrodes and separator is improved, but air permeability decreases and electrical resistance increases due to excessive compression
Solution Approach 1:
The patent applies different pressure conditions to different regions of the electrode assembly. The central part receives higher pressure to ensure adequate bonding, while the outer parts receive reduced pressure to maintain air permeability and electrical resistance within acceptable ranges. This localized pressure differentiation resolves the contradiction between achieving sufficient adhesive force and preserving functional properties.
2Strength
If heat and pressure are increased to improve bonding strength, then adhesive force between electrodes and separator is improved, but electrical resistance increases due to excessive compression
Solution Approach 1:
The patent implements spatially varying pressure control where the central region of the electrode assembly is subjected to higher pressure to ensure proper bonding, while the outer regions are subjected to lower pressure. This prevents excessive compression that would increase electrical resistance, thereby resolving the contradiction between achieving adequate adhesive force and maintaining acceptable electrical resistance.
3Quantity of substance
If multiple electrodes are inserted into the electrode assembly, then capacity and energy density are improved, but heat and pressure transmission becomes non-uniform causing adhesive force variation
Solution Approach 1:
The patent implements differentiated pressure application across the electrode assembly, with the central part receiving higher pressure and outer parts receiving lower pressure. This compensates for the non-uniform heat and pressure transmission that occurs when multiple electrodes are stacked, ensuring adequate bonding throughout while maintaining adhesive force uniformity across different regions.
4Manufacturing precision
If heat press conditions are optimized for central part bonding, then adhesive force uniformity is improved, but outer portion separator experiences excessive compression
Solution Approach 1:
The patent applies lower pressure to the outer portions of the electrode assembly compared to the central part. This prevents excessive compression of the separator in outer regions while ensuring adequate bonding in the central area, thereby achieving adhesive force uniformity without causing harmful over-compression to outer separator regions.
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 solution achieves uniform bonding of electrodes and separators across the entire assembly, enhancing safety and maintaining high productivity by reducing adhesive force variations and improving stiffness.
Implementation Method 1
a first heat press step of disposing electrodes between separators and then applying heat and pressure to the electrode assembly to fix the position of the electrodes relative to the separator
Implementation Method 2
heat and pressure are not uniformly transmitted to the central part of the electrode assembly, causing a difference in adhesive force depending on the position
Data Source
AI summary
The present disclosure provides an electrode assembly including a first unit electrode assembly to an n-th unit electrode assembly (n is a natural number of 3 or more), wherein the unit electrode assembly has cathodes and anodes alternately disposed between separators folded in a zigzag manner, the cathodes and the anodes are each bonded to adjacent separators, and the i+1-th unit electrode assembly (i is a natural number of 1 to n−1) is stacked on the i-th unit electrode assembly, and a method for manufacturing the same.