Understanding a Novel Electrode Plate for Rechargeable Batteries: Simple Insights for Better Batteries

Let’s break down a new patent application for an improved electrode plate in rechargeable batteries. We’ll look at why this invention matters, how it’s different from what’s come before, and what makes it special. If you’re curious about battery technology or want to know what’s next in powering our world, you’re in the right place.

Background and Market Context

Rechargeable batteries are everywhere. From the phones in our pockets to the electric cars on our streets, batteries help keep life running. But batteries are not perfect. They can be bulky, they sometimes wear out too soon, and making them in the right shape and size can be a real challenge. Companies are always looking for ways to make batteries safer, longer lasting, and easier to fit into all sorts of gadgets and machines.

One common battery design is the “pouch battery.” Imagine a stack of thin layers—some layers store power (these are called electrode plates), and some layers keep the plates from touching each other (these are separators). All of this goes inside a soft pouch. The pouch battery is popular because it’s light and can be shaped to fit many devices, from watches to laptops.

But there’s a problem. When you make lots of these thin plates and stack them up, even the smallest mistake in how thick each plate is can mess up the whole battery. If one part sticks out more than it should, the battery may not fit right, and it could even be unsafe. Manufacturers want the plates to be as flat and even as possible. Any bumps or extra thickness can waste space, cause trouble in the battery, or lead to poor performance.

As more people use electric cars, smart devices, and energy storage for homes, the demand for better batteries grows. Battery makers need new ways to keep their products safe, reliable, and easy to build. That’s where the invention we are looking at comes in. It’s about making electrode plates in batteries that are flatter, safer, and easier to stack without causing problems.

Scientific Rationale and Prior Art

To understand why this new electrode plate is special, let’s first talk about how electrode plates are usually made and what can go wrong.

Each electrode plate starts with a base layer called the substrate. This is often a thin metal foil that helps carry electricity in the battery. On top of this foil, a special material (called the active material) is added. This active material is what stores and releases energy as the battery charges and discharges. Both the positive (cathode) and negative (anode) plates have their own types of active material.

Usually, the active material is coated onto the substrate as a paste or film. It dries to form a solid layer. This layer needs to be even and smooth. Sometimes, to protect the edges of the active material from damage or to keep it from peeling off, a thin “protective member” (like a tape or film) is added around the edge.

Here’s the catch: if you simply stick a protective tape on top of the active material, the tape can form a bump. When you stack many plates, all these bumps add up, making the battery thicker than planned. This extra thickness wastes space and can make stacking uneven, leading to problems in the battery. If the bumps are too high, they can even cause the battery pouch to bulge or tear.

People have tried to fix this by using thinner tapes or changing how the tape is applied. Some have made the active material thinner near the edges, hoping the tape won’t stick out as much. Others have tried different shapes for the protective member. But these fixes are not perfect. Often, the protective tape still sticks out a little, or the edge of the active material becomes weak and can break off. This can cause the battery to fail sooner than it should.

There are also other ways to make the plates, like using different materials or new coating methods. But these can be expensive, hard to scale up, or may require changing the whole battery design. What battery makers really want is a simple way to keep the plates flat, with strong edges, using materials and machines they already have.

This is where the new invention steps in. It’s not about replacing everything, but about carefully designing the layers so the protective part fits in smoothly—no bumps, no wasted space, and no weak edges. It’s a small change, but with big benefits.

Invention Description and Key Innovations

This invention is about a new way to build the electrode plate, the flat piece inside a battery that helps store and release energy. Let’s take a closer look at what’s new and why it matters.

The electrode plate in this invention has three main parts: a substrate (the base), an active material layer (the energy-storing layer), and a protective member (the cover that guards the edge).

In the old way, the protective member was just stuck on top, causing a bump. In this new invention, the active material layer is made in two steps:

First, a first active material portion is placed onto the substrate. This forms the main flat part of the plate. Then, a second active material portion is added. This second portion does two things: it covers the edge of the first layer and forms a “multi-stage” end. Think of it like a step or a little ledge at the edge of the plate. Part of the second layer is higher (the multi-stage part), and part is lower (the edge part). This creates a smooth place for the protective member to sit.

The protective member is then placed partly on the lower edge portion and partly on the substrate. Because of the step shape, the protective member doesn’t stick out above the active material layer. It fits neatly into the step, so the whole plate stays flat. When many plates are stacked, there are no big bumps, and the stack is smooth and even.

Why is this important? Because it solves the bump problem without making the edge weak. The protective member keeps the active material from peeling off, while the step shape keeps everything flat. The result is a battery that’s the right size, stacks well, and is safer to use.

This design works for both the positive and negative plates. The active material can be any common material used in lithium batteries, including lithium cobalt oxide, lithium iron phosphate, and even newer materials like silicon or tin for negative plates. The protective member can be a thin film or a tape, as long as it fits in the step and doesn’t stick out.

The patent also covers different ways to make the layers. The first and second active material portions can be made from the same material or different ones, depending on what works best. The edge can be made just as thick as the main layer, or a bit thinner, giving manufacturers flexibility. And the process can use the same machines already used in battery factories, making it easy to adopt.

What about the rest of the battery? The invention isn’t just for one plate—it can be used for the entire battery stack. The plates are stacked with separators in between, then all put inside a pouch or case. The result is a battery that is flatter, more reliable, and easier to make in many shapes and sizes.

To sum up, the key innovations here are:

– A multi-stage end on the active material layer, creating a step for the protective member.
– The protective member fits flush, so the plate stays flat.
– The design works with common materials and manufacturing tools.
– Battery stacks are smoother and safer, with less wasted space.

All these changes may seem small, but together they make a big difference for battery makers and users.

Conclusion

Batteries power our world, and every small improvement makes life better for everyone. This new electrode plate design is a smart solution to a simple problem. By adding a step at the edge and fitting the protective member into it, the invention keeps battery plates flat and safe. It’s easy for manufacturers to use, works with the materials they already have, and leads to better, more reliable batteries for everything from phones to cars. In battery technology, the smallest details can have the biggest impact. This invention is a great example of that.