System and method for cutting tabs in battery cell foil for stacking battery cells
By using coil rollers and displaceable guide element support members in the battery cell foil cutting system, combined with laser cutting technology, the problem that the existing system cannot adjust the length of the tab is solved, and flexible tab length control is achieved, reducing production costs and complexity.
Patent Information
- Application Number
- CN202311511127.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-09-07
- Filing Date
- 2023-11-14
- Publication Date
- 2025-03-07
AI Technical Summary
Existing battery cell foil cutting systems cannot adjust the tab length without interrupting the manufacturing process, resulting in increased production costs and complexity.
Using a coil roller and a displaceable guide element support member, a plurality of tabs are formed by a laser, and the guide element support member is selectively moved by a control system to change the tab length.
The formation of adjustable length tabs in the battery cell foil is achieved, avoiding production interruptions and reducing production costs and complexity.
Smart Images
Figure CN119581469A_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to the field of battery manufacturing, and more particularly, to systems and methods for cutting tabs in battery cell foils used in stacking battery cells. Background Art
[0002] The battery cell is formed of stacked foils separated from each other by an insulator. A first portion of the stacked foils is connected to form the cathode of the battery cell, and a second portion of the stacked foils is connected to form the anode of the battery cell. Typically, a laser cuts notches in the foil. The notches form tabs of uniform length that become connection points. A welding plate moves across the tabs to fold the tabs before welding.
[0003] The uniform length of the tabs creates overlapping surfaces when folded. Overlapping surfaces do not create a strong joint during welding. Changing the length of the tabs is not practical. The tabs are cut while the foil is moving, so changing the tab length would require stopping the foil, changing the laser settings, and restarting the foil. The time and effort required to change tab settings increases production costs and increases production complexity. Therefore, it is desirable to provide a system that will provide adjustable tab length without interrupting the manufacturing process. Summary of the invention
[0004] According to a non-limiting example, a system for forming a tab in a battery cell foil includes a web roll and a guide element support member, the web roll including a surface, the guide element support member being displaceably connected to the web roll. The guide element support member includes a guide element support surface that is substantially coplanar with the surface of the web roll. A plurality of guide elements are supported on the guide element support member. Each of the plurality of guide elements is associated with a different tab size. The plurality of guide elements are selectively displaceable relative to the surface of the web roll. A tab cutting mechanism, the tab cutting mechanism being directed to one of the plurality of guide elements. A control system is operably connected to the guide element support member. The control system is operable to selectively displace a selected guide element of the plurality of guide elements into alignment with the tab cutting mechanism so as to selectively control the dimensional properties of a tab formed in the moving battery cell foil.
[0005] In addition to one or more features described herein, the splice cutting mechanism includes a laser.
[0006] In addition to one or more features described herein, the web roll includes a cylinder having a first end and a second end, the cylinder defining a web roll axis, the surface being defined between the first end and the second end.
[0007] In addition to one or more features described herein, the guiding element support member is disposed at the first end and is rotatable about the web roll axis.
[0008] In addition to one or more features described herein, the plurality of guide elements include a first guide element having a first dimension defined along the web roller axis, a second guide element having a second dimension defined along the web roller axis that is larger than the first dimension, and a third guide element having a third dimension defined along the web roller axis that is larger than the second dimension.
[0009] In addition to one or more features described herein, each of the plurality of guide elements is circumferentially spaced apart from other guide elements of the plurality of guide elements along the guide element support member.
[0010] In addition to one or more features described herein, a quantity of battery foil is passed through a web roll and a tab cutting mechanism forms a plurality of tabs in the battery foil.
[0011] According to a non-limiting example, a method of forming a tab in a battery cell foil includes passing the battery cell foil over a web roll having a web roll axis, supporting a portion of the battery cell foil on a guide element support member including a plurality of guide elements, guiding a tab cutting mechanism at a first of the plurality of guide elements, cutting a first tab in the portion of the battery cell foil, the first tab having a first size corresponding to the first of the plurality of guide elements, displacing the guide element support member as the battery cell foil passes over the web roll to align a second of the plurality of guide elements with the tab cutting mechanism, and cutting a second tab in the portion of the battery cell foil, the second tab having a second size different from the first size, the second size corresponding to the second of the plurality of guide elements.
[0012] In addition to one or more features described herein, the guide tab cutting mechanism includes aiming a laser at a first guide element of the plurality of guide elements.
[0013] In addition to one or more features described herein, the cutting tab includes passing a laser through the battery cell foil into a first guide element of the plurality of guide elements.
[0014] In addition to one or more features described herein, passing the laser through the battery cell foil includes directing the laser to follow a pattern embodied by a first directing element of the plurality of directing elements.
[0015] In addition to one or more features described herein, the method also includes further displacing the guide element support member as the battery cell foil passes over the web roll to align a third guide element of the plurality of guide elements with the tab cutting mechanism.
[0016] In addition to one or more features described herein, a third tab is cut in the portion of the battery cell foil, the third tab having a third size different from the first size and the second size, the third size corresponding to a third guide element of the plurality of guide elements.
[0017] In addition to one or more features described herein, displacing the guiding element support member includes rotating the guiding element support member relative to the web roll.
[0018] In addition to one or more features described herein, cutting the first tab having the first size includes forming the first tab having a first length defined along a web roll axis of the web roll.
[0019] In addition to one or more of the features described herein, cutting the second tab having the second size includes forming the second tab having a second length defined along a web roll axis of the web roll.
[0020] In addition to one or more features described herein, forming the second tab having a second length includes forming the second tab shorter than the first tab.
[0021] In addition to one or more features described herein, a battery cell is formed by the method.
[0022] In addition to one or more features described herein, directing the splice cutting mechanism at the first guide element of the plurality of guide elements includes activating a laser.
[0023] In addition to one or more features described herein, activating the laser includes passing the laser through the cell foil and tracing a pattern defined by a first guide element of the plurality of guide elements to form a first tab.
[0024] The above features and advantages and other features and advantages of the present disclosure are apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Other features, advantages and details appear, by way of example only, from the following detailed description, which refers to the accompanying drawings, in which:
[0026] Figure 1 is a schematic diagram of a web roll and a displaceable guide element portion of a splice cutting system according to a non-limiting example;
[0027] Figure 2 is a schematic diagram of a splice cutting mechanism according to a non-limiting example, the splice cutting mechanism being directed past Figure 1 a web roll and a film over a displaceable guiding element;
[0028] Figure 3 is a plan view of a film with a splice size that varies on the fly by a splice cutting system according to a non-limiting example; and
[0029] Figure 4 is a plan view of two battery cells formed by a tab cutting system according to a non-limiting example. DETAILED DESCRIPTION
[0030] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or use. It should be understood that throughout the drawings, corresponding reference numerals represent identical or corresponding components and features. As used herein, the term module refers to a processing circuit, which may include an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated or group) and memory that executes one or more software or firmware programs, a combinational logic circuit, and / or other suitable components that provide the described functionality.
[0031] A system for forming a tab in a battery cell foil according to a non-limiting example Figure 1 and Figure 2 10. The splice forming system 10 includes a web roll 12 shown in the form of a cylinder 14. At this point, it should be understood that the web roll 12 can take a variety of forms. The web roll 12 includes a first end 20, a second end 22, and an outer surface 24 extending between the first end 20 and the second end 22. The web roll 12 includes a web roll axis "A" extending between the first end 20 and the second end 22.
[0032] In a non-limiting example, a guide element support member 34 having a guide element support surface 36 is displaceably mounted at the first end 20 of the web roll 12. In a non-limiting example, the guide element support member 34 can be selectively rotated relative to the cylindrical body 14 about the web roll axis "A", as will be described in detail herein. A plurality of guide elements 42 are arranged on the guide element support surface 36. In the non-limiting example shown, the plurality of guide elements 42 include a first guide element 44, a second guide element 46, and a third guide element 48 that are circumferentially spaced from each other on the guide element support surface 36. Obviously, the number of guide elements can vary.
[0033] In a non-limiting example, the first guide element 44 includes a first dimension "D1" measured along the web roll axis "A". The second guide element 46 includes a second dimension "D2" measured along the web roll axis "A". The third guide element 48 includes a third dimension "D3" measured along the web roll axis "A". In a non-limiting example, D1 is greater than D2 and D3, and D2 is greater than D3. At this point, it should be understood that the specific order and relative positions of the first guide element 44, the second guide element 46, and the third guide element 48 can vary. As will be described in detail herein, each of the first guide element 44, the second guide element 46, and the third guide element 48 is associated with forming a foil tab of a selected length.
[0034] In a non-limiting example, the splice cutting mechanism 60 is disposed outside the web roll 12, such as Figure 2 The splice cutting mechanism 60 includes a fixedly mounted laser 64 that is directed toward the guide element support surface 36. In a non-limiting example, the guide element support member 34 is selectively positioned so that one of the plurality of guide elements 42 is aligned with the laser 64. As will be described in more detail herein, the guide element support member 34 is selectively rotated about the web roll axis "A" to position one of the first guide element 44, the second guide element 46, and the third guide element 48 to be aligned with the laser 64. As will also be described in more detail herein, the guide element support member 34 can be rotated without interrupting the splice cutting operation.
[0035] In a non-limiting example, the control system 70 ( Figure 1 ) is operably connected to the guide element support member 34. The control system 70 may be directly wired to the guide element support member 34 or connected via one or more wireless communication protocols. The control system 70 includes a central processing unit (CPU) 72, a guide element control module 74, and a memory 76. The control system 70 receives information, which may be in a programmed form, via input 78 and controls the position of the guide element support member 34 relative to the web roll 12 to form a splice in the continuous battery cell foil 80, such as Figure 3 shown.
[0036] In a non-limiting example, a continuous cell foil 80 traverses the outer surface 24 of the web roll 12. An outer edge portion 84 of the cell foil 80 passes over the guide element support surface 36 of the guide element support member 34. One of the plurality of guide elements 42 is aligned with the laser 64. In a non-limiting example, the third guide element 48 can be centered under the laser 64. The laser 64 can be activated and controlled to track the pattern defined by the third guide element 48. The laser 64 passes through the cell foil 80 into the third guide element 48 to form a first tab 86 having a size D3. The number of first tabs 86 produced can vary.
[0037] After producing the selected number of first tabs 86, the control system 70 displaces the guide element support member 34 to align the second guide element 46 with the laser 64. The second guide element 46 is aligned with the laser 64 without stopping the movement of the cell foil 80 on the outer surface 24 of the web roll 12. Thus, a second plurality of tabs 88 are formed in the outer edge portion 84 of the cell foil 80 without interrupting the workflow. In a non-limiting example, once the second guide element 46 is in place, the laser 64 can be activated and controlled to track the pattern defined by the second guide element 46. The laser 64 passes through the cell foil 80 into the second guide element 46 to form a second tab 88 having a size D2. The number of second tabs 88 produced can vary.
[0038] After the selected number of second tabs 88 are produced, the control system 70 displaces the guide element support member 34 to align the first guide element 44 with the laser 64. The first guide element 44 is aligned with the laser 64 without stopping the movement of the cell foil 80 on the outer surface 24 of the web roll 12. Thus, a third plurality of tabs 90 are formed in the outer edge portion 84 of the cell foil 80 without interrupting the workflow. In a non-limiting example, once the first guide element 44 is in place, the laser 64 can be activated and controlled to track the pattern defined by the first guide element 44. The laser 64 passes through the cell foil 80 into the first guide element 44 to form a third tab 90 having a dimension D1. The number of third tabs 90 produced can vary.
[0039] In a non-limiting example, the battery cell foil 80 may be separated into individual sheets to form the battery cells 94, such as Figure 4As shown. The battery cell 94 includes a plurality of foils 96 that define a cathode (such as shown at 98) and an anode (such as shown at 100). Each cathode, anode pair is separated by a separator 104. A first portion 106 of the cathode 98 may include a plurality of tabs having a first length, and a second portion 108 of the cathode 98 may include a tab having a second length. Similarly, a first portion 110 of the anode 100 may include a plurality of tabs having a first length, and a second portion 112 of the anode 100 may include a tab having a second length. By varying the length of the tabs, the welded connections may overlap more easily to produce a more robust and reliable welded connection.
[0040] The terms "one" and "an" do not indicate a limitation of quantity, but rather indicate the presence of at least one of the referenced item. Unless the context clearly indicates otherwise, the term "or" means "and / or". References to "aspects" throughout the specification mean that a particular element (e.g., a feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in the various aspects.
[0041] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements present.
[0042] Unless otherwise indicated herein, all test standards are the most current standards in effect as of the filing date of this application or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.
[0043] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.
[0044] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from its scope. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the disclosure without departing from the basic scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.
Claims
1. A system for forming a tab in a battery cell foil, comprising: a web roll comprising a surface; a guide element support member displaceably connected to the web roll, the guide element support member comprising a guide element support surface that is substantially coplanar with the surface of the web roll; a plurality of guide elements supported on the guide element support member, each of the plurality of guide elements being associated with a different splice size, the plurality of guide elements being selectively displaceable relative to the surface of the web roll; a web cutting mechanism directed toward one of the plurality of guide elements; as well as A control system operably connected to the guide element support member, the control system operable to selectively displace selected ones of the plurality of guide elements into alignment with the tab cutting mechanism to selectively control dimensional properties of tabs formed in the moving battery cell foil.
2. The system according to claim 1, wherein: The splice cutting mechanism includes a laser.
3. The system according to claim 1, wherein: The web roll includes a cylindrical body having a first end and a second end, the cylindrical body defining a web roll axis, the surface being defined between the first end and the second end.
4. The system according to claim 3, wherein: The guiding element support member is arranged at the first end and is rotatable about the web roll axis.
5. The system according to claim 4, wherein: The plurality of guide elements include a first guide element having a first dimension defined along the web roller axis, a second guide element having a second dimension defined along the web roller axis, the second dimension being greater than the first dimension, and a third guide element having a third dimension defined along the web roller axis, the third dimension being greater than the second dimension.
6. The system according to claim 1, wherein: Each of the plurality of guide elements is circumferentially spaced apart from other guide elements of the plurality of guide elements along the guide element support member.
7. A method of forming a tab in a battery cell foil, comprising: passing the battery cell foil over a web roll having a web roll axis; supporting a portion of the battery cell foil on a guide element support member including a plurality of guide elements; guiding a web cutting mechanism at a first guide element of the plurality of guide elements; cutting a first tab in the portion of the battery cell foil, the first tab having a first size corresponding to the first guide element of the plurality of guide elements; displacing the guide element support member to align a second guide element of the plurality of guide elements with the tab cutting mechanism as the battery cell foil passes over the web roll; as well as A second tab is cut in the portion of the battery cell foil, the second tab having a second dimension different from the first dimension, the second dimension corresponding to the second guide element of the plurality of guide elements.
8. The method according to claim 7, wherein: Directing the splice cutting mechanism includes aiming a laser at the first guide element of the plurality of guide elements.
9. The method of claim 7, further comprising further displacing the guide element support member as the battery cell foil passes over the web roll to align a third guide element of the plurality of guide elements with the tab cutting mechanism.
10. The method according to claim 7, wherein: Displacing the guiding element support member includes rotating the guiding element support member relative to the web roll.