Zigzag Electrode Assembly to Prevent Plate Curling
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Solution Overview
Problem
Existing secondary battery electrode assemblies face inefficiencies in process time and potential electrode plate curling during manufacturing, particularly when stacking multiple electrode plates, which can lead to low current density and increased cell thickness.
Innovation Solution
The electrode assembly incorporates two separators bent in a zigzag manner to align and fix a single or multiple first electrode plates, with a second electrode plate inserted from the outside, utilizing a fixing part made of materials like polyimide, polypropylene, or polyethylene terephthalate for adhesion or fusion to secure the plates and prevent curling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple electrode plates are stacked using conventional single-separator methods, then the battery capacity increases, but the process time increases and electrode plate curling occurs
Solution Approach 1:
The invention divides the stacking process into two independent stages: first stacking odd-numbered electrode plates with a first separator, then stacking even-numbered electrode plates with a second separator. This segmentation allows parallel processing of different electrode plate groups, reducing total manufacturing time while preventing curling through dedicated fixing parts for each group.
Solution Approach 2:
The invention introduces a dual-separator configuration where separators are arranged in alternating positions (first separator between odd plates, second separator between even plates). This dimensional arrangement enables independent fixing of different electrode plate groups, allowing twice as many plates to be stacked without increasing process time or causing curling.
2Quantity of substance
If multiple electrode plates are stacked using conventional methods, then the battery capacity increases, but electrode plate curling occurs leading to low current density
Solution Approach 1:
The invention segments the electrode plate stacking into two distinct groups (odd and even numbered plates) with dedicated separators and fixing parts for each group. This segmentation ensures that each electrode plate is independently positioned and fixed, preventing curling and maintaining alignment precision even when stacking multiple plates.
Solution Approach 2:
The invention uses fixing parts as intermediary elements between the electrode plates and separators. These fixing parts act as mediators that secure each electrode plate in its proper position, preventing curling and ensuring precise alignment. The fixing parts are specifically positioned at corresponding locations on alternating electrode plates, providing stable fixation without causing deformation.
3Quantity of substance
If more electrode plates are stacked, then the battery capacity increases, but cell thickness increases
Solution Approach 1:
The invention arranges electrode plates and separators in an alternating pattern along the stacking direction, with first separators between odd plates and second separators between even plates. This dimensional arrangement allows compact stacking of twice as many electrode plates within the same cell thickness, effectively doubling the plate density without increasing overall cell dimensions.
4Device complexity
If conventional single separator method is used, then the manufacturing process is simple, but only limited number of electrode plates can be stacked
Solution Approach 1:
The invention segments the separator function into two distinct separators (first separator for odd plates, second separator for even plates), each with dedicated fixing parts. This segmentation allows the system to handle twice as many electrode plates while maintaining a relatively simple manufacturing process, as each separator group can be processed independently using similar techniques.
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
This configuration enhances process efficiency by allowing twice as many electrode plates to be stacked with the same process, while minimizing electrode plate curling and ensuring effective separation to prevent short circuits, thereby improving the overall performance of the secondary battery.
Implementation Method 1
The fixing part may include polyimide (PI), polypropylene (PP), or polyethylene terephthalate (PET). The aligning may further include fixing at least partial regions of the first electrode plate to the separator through fusion or adhesion.
Implementation Method 2
The fixing part may be formed through fusion or adhesion.
Data Source
Figure 1
Figure 2A
Figure 2B~2C
AI summary
An electrode assembly includes two separators, at least one first electrode plate between the two separators, the at least one first electrode plate being aligned with the two separators into a zigzag shape, and second electrode plates coupled to the zigzag shape opposite to the at least one first electrode plate, the second electrode plate being outside of the two separators.