Zigzag Separator 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 reduced current density and increased cell thickness.
Innovation Solution
The electrode assembly incorporates two separators bent in a zigzag manner to align and fix multiple first electrode plates, with a second electrode plate inserted from the outside, using a fixing part made of materials like polyimide, polypropylene, or polyethylene terephthalate for adhesion or fusion, to enhance stacking efficiency and prevent curling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple electrode plates are stacked using conventional single separator method, then the battery capacity can be increased, 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 the first separator, then stacking even-numbered electrode plates with the second separator. This segmentation allows parallel processing of different electrode plate groups, reducing total manufacturing time while preventing curling through the fixing part structure.
Solution Approach 2:
The fixing part acts as an intermediary element that connects the separator to the electrode plate, providing stable adhesion and preventing relative movement or curling during the stacking process. This intermediary structure enables reliable multi-plate stacking without the curling issues that plague conventional methods.
2Quantity of substance
If multiple electrode plates are stacked using conventional method, then the battery capacity can be increased, but electrode plate curling occurs reducing current density
Solution Approach 1:
The fixing part is formed on the separator before electrode plate stacking, creating a pre-prepared adhesion structure that prevents electrode plate curling from the outset. This preliminary action ensures proper alignment and flatness are maintained throughout the stacking process, preserving current density even as plate count increases.
Solution Approach 2:
The fixing part serves as an intermediary that mediates between the separator and electrode plate, ensuring stable connection and preventing relative displacement or curling. This intermediary structure maintains manufacturing precision by eliminating the curling phenomenon that occurs in conventional stacking methods.
3Quantity of substance
If more electrode plates are stacked, then the battery capacity increases, but the cell thickness increases
Solution Approach 1:
By dividing the stacking process into two separate operations using two separators, the invention achieves more compact arrangement of multiple electrode plates. The segmentation allows for optimized space utilization, increasing plate count while controlling overall cell thickness through efficient layering.
4Device complexity
If conventional stacking method is used, then the manufacturing process is simple, but the process efficiency is low
Solution Approach 1:
The stacking process is segmented into two independent operations that can be performed in parallel or sequence, significantly improving throughput. While the process structure is divided, each segment remains relatively simple, maintaining ease of implementation while doubling the stacking efficiency through the two-separator configuration.
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 approach significantly increases 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.
Implementation Method 1
The fixing part may include polyimide (PI), polypropylene (PP), or polyethylene terephthalate (PET). The fixing part may be formed through fusion or adhesion.
Data Source
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.