A process for high-ratio rolled multipole lugs

Abstract

This invention discloses a process for high-ratio multi-tab winding, comprising the following steps: Preparation stage: preparing the sheet to be coated, coating the sheet using the gap zebra coating method; First continuous slitting: slitting the coated sheet into multiple strips, and continuously rolling the strips to improve surface flatness and consistency; Continuous die-cutting: continuously die-cutting the rolled strips, the die-cutting process including: cutting multi-tabs on the upper and lower surfaces of the strip; the die-cutting process is continuous, maintaining the overall continuity of the strip; Fully automatic winding: fully automatically winding the die-cut strips, using a positioning sensing area to ensure winding accuracy and neatness; Second slitting: slitting the wound strips along the center position. This invention uses the gap zebra coating method followed by die-cutting to achieve continuous fully automatic winding, and finally slitting, balancing accuracy, efficiency, and cost.

Description

Technical Field

[0001] This invention relates to the field of polymer lithium-ion battery processing, specifically to a process method for high-rate multi-tab stacking. Background Technology

[0002] With the continuous development of lithium-ion battery technology, high-rate lithium-ion batteries are increasingly being used in start-stop systems and drones, which require high energy density and fast response, due to their superior charge-discharge performance and high power output. However, the traditional manufacturing process of high-rate lithium-ion batteries usually adopts stacking or multi-tab winding processes, which have problems such as low efficiency, high equipment cost, and poor uniformity.

[0003] Traditional electrode die-cutting processes primarily rely on stencil die-cutting or laser die-cutting technologies. While stencil die-cutting reduces costs to some extent, the multiple slitting and semi-automatic winding processes easily lead to uneven winding, resulting in poor product consistency and low production efficiency. On the other hand, laser die-cutting offers high precision, but the equipment and molds are expensive, especially in large-scale production, making effective cost control difficult. Furthermore, metal die-cutting technology is also limited by rapid mold wear and high maintenance costs, making it difficult to meet the demands of mass production.

[0004] In existing technologies, some process improvement methods, such as zebra coating, attempt to improve the positioning accuracy and winding uniformity of the tabs by coating strip-shaped coating areas and empty foil areas on the sheet. However, most existing coating and winding processes require steps such as applying adhesive to positioning points and creating openings, which increases the complexity of the process. Furthermore, the discontinuous winding process further affects production efficiency and product consistency. Therefore, there is an urgent need for a high-ratio multi-tab manufacturing process that can reduce equipment and maintenance costs while simultaneously achieving high efficiency, winding uniformity, and positioning accuracy. Summary of the Invention

[0005] To address the aforementioned issues, this invention provides a process for high-rate multi-tab winding, employing a gap zebra coating method and stencil die-cutting technology. By simplifying the process flow, eliminating adhesive application and hole-opening steps, and achieving continuous positioning sensing during the winding process, the winding efficiency and uniformity are significantly improved, while reducing equipment and maintenance costs. This method is suitable for large-scale production of high-rate lithium-ion batteries.

[0006] This invention is achieved through the following technical solution: a process for high-ratio rolled multi-pole tabs, comprising the following steps:

[0007] (1) Preparation stage:

[0008] Prepare the sheet to be coated, and apply the coating to the sheet using the gap zebra coating method. The coating method forms gaps and coating areas on the sheet, which are used to provide a predetermined position for subsequent tab punching and to provide positioning sensing function during continuous die cutting and fully automatic winding.

[0009] (2) First continuous slicing:

[0010] The coated sheet is cut into multiple strips and then continuously rolled to improve surface flatness and consistency.

[0011] (3) Continuous offset die-cutting:

[0012] The rolled strip is continuously die-cut using a stencil. The die-cutting process includes:

[0013] Cut multi-pole tabs on the upper and lower surfaces of the strip;

[0014] The die-cutting process is carried out continuously to maintain the overall continuity of the material strip;

[0015] (4) Fully automatic winding:

[0016] The die-cut strip is automatically wound up, and the positioning sensing area is used to ensure the accuracy and neatness of the winding during the process;

[0017] (5) Second cutting:

[0018] After the material strip is wound up, it is cut along the center position to obtain two separate material strip parts.

[0019] As a preferred technical solution, the gap zebra coating method includes the following steps:

[0020] Multiple equidistant transverse coating zones are formed in the transverse direction of the sheet;

[0021] A longitudinal gap area is provided between the transverse coating areas to serve as the fiber optic positioning sensing area during continuous die-cutting and fully automatic winding processes;

[0022] Empty foil areas are formed on both sides of the sheet, reserving positions for electrode tab punching;

[0023] Metal foil is filled in the longitudinal gap area to replace the traditional adhesive and hole-opening process, thereby realizing the positioning sensing function.

[0024] As a preferred technical solution, the continuous offset die-cutting process simultaneously die-cuts the tabs on both the upper and lower sides, ensuring that the relative position of each tab on the strip remains consistent.

[0025] As a preferred technical solution, the die-cutting process uses a PVC die-cutting machine to punch the tab area during the die-cutting process to avoid interruption of the material strip.

[0026] As a preferred technical solution, during the second slitting process, the slitting machine cuts along the center of the strip, dividing the strip into two parts.

[0027] The beneficial effects of this invention are: traditional multi-pole ear manufacturing processes usually employ semi-automatic winding, resulting in low production efficiency; this invention, by adopting a continuous automatic winding process, combined with gap zebra coating and continuous stencil die-cutting technology, achieves continuous positioning and automatic winding of multi-pole ears, significantly improving production efficiency and meeting the needs of large-scale, high-speed production.

[0028] This invention sets gaps and coating zones during the sheet coating process, and combines them with metal foil in the longitudinal gap zone for fiber optic positioning sensing, so that the tabs maintain a high degree of consistency during the winding process. Compared with the traditional segmented winding process, this invention can achieve continuous and precise winding operation, significantly improve winding neatness, and thus improve the overall quality and performance of the battery cell.

[0029] This invention abandons the high-cost methods of traditional laser die-cutting or metal die-cutting, and instead adopts a PVC die-cutting process, which can achieve precise punching of the tabs at a lower cost. At the same time, by eliminating the steps of applying adhesive and making holes in the traditional process, material consumption and additional maintenance requirements are reduced, thereby further reducing equipment and maintenance costs and improving economic efficiency.

[0030] Traditional processes require adhesive application for tab cutting and fiber optic sensing positioning via perforation, which is complex and prone to errors. This invention achieves positioning sensing by setting a gap area and filling it with metal foil during sheet coating, eliminating the need for adhesive application and perforation, simplifying the process, reducing the possibility of errors, and improving process stability. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is a coating outline diagram of the present invention;

[0033] Figure 2 This is a schematic diagram of the pre-roll pressing slitting shape of the present invention;

[0034] Figure 3 This is a view of the continuously die-cut electrode tab of the present invention.

[0035] Figure 4 This is a diagram showing the continuous die-cutting and subsequent continuous slitting shape of the present invention. Detailed Implementation

[0036] All features disclosed in this specification, or steps in all methods or processes disclosed herein, may be combined in any way, except for mutually exclusive features and / or steps.

[0037] Any feature disclosed in this specification (including any appended claims, abstract, and drawings) may be replaced by other equivalent or similar features for a similar purpose, unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is merely one example of a series of equivalent or similar features.

[0038] This invention provides a process for high-rate multi-tab winding, suitable for the fabrication of high-rate polymer lithium-ion cells. This method achieves high-efficiency production, high winding uniformity, and low equipment cost by employing a gap zebra coating method, continuous die-cutting, and fully automated winding process. Specific implementation details are as follows:

[0039] Step (1): Preparation stage

[0040] In the implementation of this invention, a sheet material suitable for lithium-ion battery cells is first prepared. The sheet material can be selected from various polymer composite materials suitable for lithium battery processes. The sheet thickness can be selected according to different application scenarios to meet the energy density and power output requirements of different products.

[0041] like Figure 1 As shown, after the sheet is prepared, it is coated using the gap zebra coating method. The characteristic of this coating method is that it forms multiple transverse coating areas 2 and longitudinal gap areas 1 on the surface of the sheet, thus providing a foundation for subsequent tab punching and positioning sensing. During the coating process, the design of the transverse coating areas and longitudinal gap areas can be adjusted according to specific process requirements to ensure accurate positioning during tab punching and winding. Empty foil areas 3 are formed on both sides of the sheet, reserving space for tab punching.

[0042] The coating material should be selected to ensure good tab performance after die-cutting, while also possessing appropriate adhesion and stability to accommodate subsequent winding processes. The coating equipment should have a high-precision coating control system to ensure the uniformity and stability of the coating.

[0043] like Figure 2 As shown, step (2): first continuous slicing

[0044] The coated sheet will be slit for the first time by a slitting machine. The purpose of slitting is to divide the whole sheet into multiple strips to accommodate the subsequent winding process.

[0045] The slit strips undergo a rolling process to improve surface flatness and thickness consistency, ensuring no folds or irregularities occur during winding. The pressure and speed during rolling can be adjusted according to the specific material of the sheet to achieve optimal flatness and thickness control.

[0046] like Figure 3 As shown, step (3): continuous die-cutting

[0047] After roll forming, the strip enters the continuous die-cutting stage. This process allows for simultaneous tab cutting on both the upper and lower surfaces of the strip.

[0048] During the die-cutting process, the upper and lower dies operate synchronously to ensure that tab structures are formed simultaneously on both the upper and lower surfaces of the strip. During die-cutting, a fiber optic positioning sensor system monitors the position of the strip to ensure that the relative position of each tab is accurate and consistent.

[0049] In die-cutting equipment, the die design should be adapted to the strip width and tab size to ensure strip continuity and tab cutting quality during high-precision die-cutting. The fiber optic positioning system uses the longitudinal gap area in the gap zebra coating method for sensing, achieving precise positioning and ensuring high efficiency in die-cutting.

[0050] Step (4): Fully automatic winding

[0051] After die-cutting, the strip enters the fully automatic winding stage.

[0052] In this process, a fully automated winding machine is used for the winding operation, and a positioning sensing system is used during the winding process to ensure winding accuracy and neatness. Controlling the winding speed and tension are key factors in ensuring neat winding of the strip. The tension control system of the winding machine ensures that the strip is always under appropriate tension during the winding process, thereby preventing irregular folding or loosening of the strip during winding.

[0053] The fully automatic winding equipment is also equipped with a real-time monitoring system that uses sensors to monitor the accuracy of each winding turn, ensuring the precise and consistent position of the tabs.

[0054] like Figure 4 As shown, step (5): second cutting

[0055] After winding, the strip will be slit a second time by a slitting device. The purpose of this step is to cut the wound strip along the center position to obtain two separate strip sections.

[0056] During the slitting process, the slitting equipment uses high-precision cutting tools or other cutting techniques to cut along the center of the material strip, ensuring the symmetry and integrity of each separated strip. The slitting equipment can adjust parameters according to the width and thickness of the material strip to ensure the smoothness and accuracy of the cut.

[0057] Battery cell manufacturing suitable for lightweight equipment

[0058] When manufacturing battery cells for lightweight devices (such as drone batteries), thinner sheets are selected. A gap zebra coating process is used to create the coating and gap areas, ensuring accurate punching of the tabs in subsequent die-cutting. In a continuous offset die-cutting process, the tabs are cut simultaneously using upper and lower synchronous dies, and a fiber optic positioning system ensures punching accuracy. Finally, in a fully automated winding process, the winding equipment uses a tension control system and fiber optic sensors to ensure neat winding of the strip. After completion, a second slitting is performed to obtain battery cell strips that meet specifications.

[0059] Battery cell manufacturing suitable for heavy-duty equipment

[0060] When manufacturing high-load, start-stop batteries, thicker sheets are selected to ensure the cells have high energy density and power output. Precision coating using the gap zebra coating method and die-cutting technology allow for accurate positioning and punching of the tabs on the thicker sheets. Fully automated winding equipment adjusts tension and speed to ensure uniform winding of the thick strip, avoiding uneven winding caused by material thickness. Finally, after slitting, the finished cell strips possess high precision and consistency, meeting the requirements of high-load batteries.

[0061] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions conceived without inventive effort should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A process for high-ratio rolled multi-pole tabs, characterized in that, Includes the following steps: (1) Preparation stage: Prepare the sheet to be coated, and apply the coating using the gap zebra coating method. The gap zebra coating method creates gaps and coating areas on the sheet, providing predetermined positions for subsequent tab punching and providing positioning sensing during continuous die-cutting and fully automated winding. The gap zebra coating method includes the following steps: Multiple equidistant transverse coating zones are formed in the transverse direction of the sheet; A longitudinal gap area is provided between the transverse coating areas to serve as the fiber optic positioning sensing area during continuous die-cutting and fully automatic winding processes; Empty foil areas are formed on both sides of the sheet, reserving positions for electrode tab punching; Metal foil is filled in the longitudinal gap area to replace the traditional adhesive and hole-opening process, thereby realizing the positioning sensing function. (2) First continuous slicing: The coated sheet is cut into multiple strips and then continuously rolled to improve surface flatness and consistency. (3) Continuous offset die-cutting: The rolled strip is continuously die-cut using a stencil. The die-cutting process includes: Cut multi-pole tabs on the upper and lower surfaces of the strip; The die-cutting process is carried out continuously to maintain the overall continuity of the material strip; (4) Fully automatic winding: The die-cut strip is automatically wound up, and the positioning sensing area is used to ensure the accuracy and neatness of the winding during the process; (5) Second cutting: After the material strip is wound up, it is cut along the center position to obtain two separate material strip parts.

2. The process method for high-ratio rolled multi-pole tabs according to claim 1, characterized in that: The continuous offset die-cutting process involves simultaneously die-cutting the tabs on both the upper and lower sides, ensuring that the relative position of each tab on the strip remains consistent.

3. The process method for high-ratio rolled multi-pole tabs according to claim 1, characterized in that: The die-cutting process uses a PVC die-cutting machine to punch the tab area during the die-cutting process to avoid interruption of the material strip.

4. The process method for high-ratio rolled multi-pole tabs according to claim 1, characterized in that: During the second slitting process, the slitting machine cuts along the center of the strip, dividing the strip into two parts.

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