Battery electrode sheet
A battery electrode sheet comprises a conductive substrate and an electrode material coated on at least a portion of the conductive substrate. The coated portion of the conductive substrate comprises a first region, a second region, and a transition region between the first and second regions. The electrode material on the first region has a first thickness; and the electrode material on the second region has a second thickness, which is smaller than the first thickness. The electrode material on the transition region has a thickness that decreases between the first and second regions.
1. A battery electrode sheet comprising:
a rectangular conductive substrate comprising a first side, a second side, a third side, and a fourth side; wherein the first side is opposite to the third side and the second side is opposite to the fourth side; and
an electrode material coated on at least a portion of the conductive substrate to form a coated portion;
wherein the coated portion of the conductive substrate comprises a first region defined by the first side and a portion of the second side and a portion of the fourth side, a second region defined by the third side and a portion of the second side and a portion of the fourth side, and a transition region located between the first region and the second region;
wherein the electrode material on the first region has a first thickness; the electrode material on the second region has a second thickness, smaller than the first thickness; and the electrode material on the transition region has a thickness that decreases from the first region to the second region.
2. The sheet of claim 1 , wherein the first thickness is in a range of between about 20 and about 350 μm.
3. The sheet of claim 1 , wherein the second thickness is in a range of between about 10 and about 250 μm.
4. The sheet of claim 1 , wherein the ratio of the first thickness to the second thickness is in a range of between about 2:1 and about 10:1.
5. The sheet of claim 1 , wherein the thickness of the electrode material on the transition region decreases in a straight line between the first region and the second region.
6. The sheet of claim 5 , wherein the thinning of the electrode material is at a gradient of between about 5 and about 300 μm/mm.
7. The sheet of claim 1 , wherein the transition region has a width in a range of between about 1 and about 10 mm.
8. The sheet of claim 1 , wherein the second region has a width in a range of between about 1 and about 10 mm.
9. The sheet of claim 1 , wherein the first thickness is substantially uniform along the first region; and the second thickness is substantially uniform along the second region.
10. The sheet of claim 1 , wherein the substrate further comprises an exposed region at the edge of the sheet, wherein the exposed region has no electrode material coating.
11. The sheet of claim 10 , wherein the exposed region has a width in a range of between about 10 and about 100 mm.
12. The sheet of claim 1 , further comprising an insulating coating, wherein the insulation layer covers at least the transition region and the second region.
13. The sheet of claim 12 , wherein the insulating coating has a thickness in a range of between about 5 and about 150 μm.
14. The sheet of claim 12 , wherein the insulating coating comprises a material selected from the group consisting of polyphenylene sulfide, polyurethane, polyethylene, polypropylene, and combinations thereof.
15. The sheet of claim 14 , wherein the insulating coating is formed from polyphenylene sulfide.
16. A method for preparing a battery electrode sheet comprising:
coating an electrode material onto at least a portion of a conductive substrate to form a coated portion, wherein the conductive substrate has a rectangular shape, comprising a first side, a second side, a third side, and a fourth side; and wherein the first side is opposite to the third side and the second side is opposite to the fourth side;
wherein the coated portion of the conductive substrate comprises a first region defined by the first side and a portion of the second side and a portion of the fourth side, a second region defined by the third side and a portion of the second side and a portion of the fourth side, and a transition region between the first region and the second region;
wherein the electrode material on the first region has a first thickness; the electrode material on the second region has a second thickness, smaller than the first thickness; and the electrode material on the transition region has a thickness that decreases from the first region to the second region.
17. The method of claim 16 , further comprising:
removing the electrode material partially from the substrate.
18. The method of claim 16 , further comprising:
drying the coated electrode plate.
19. The method of claim 16 , further comprising:
pressing the coated electrode sheet.
20. A battery core comprising:
a cathode sheet comprising:
a rectangular conductive substrate, comprising a first side, a second side, a third side, and a fourth side; and wherein the first side is opposite to the third side and the second side is opposite to the fourth side; and
an electrode material coated on at least a portion of the conductive substrate to form a coated portion;
wherein the coated portion of the conductive substrate comprises a first region defined by the first side and a portion of the second side and a portion of the fourth side, a second region defined by the third side and a portion of the second side and a portion of the fourth side, and a transition region between the first and second regions;
wherein the electrode material on the first region has a first thickness; the electrode material on the second region has a second thickness, smaller than the first thickness; and the electrode material has a thickness that decreases from the first region to the second region;
an anode sheet; and
a separator sheet disposed between the cathode sheet and the anode sheet.