Apparatus and method for manufacturing secondary battery assembly

Abstract

An apparatus for manufacturing a secondary battery assembly, comprising: a first hopper configured to house a plurality of unit electrode battery cells; a stacking table configured to have the plurality of unit electrode battery cells stacked thereon, thereby forming a battery cell stack; a transfer unit configured to sequentially pick up a respective one of the plurality of unit electrode battery cells in the first hopper, move it to the stacking table, and place it in a one-on-top-of-another manner; a detection unit configured to detect a relative position of a unit electrode battery cell placed on top of the battery cell stack relative to another unit electrode battery cell therebelow; and a control unit configured to determine whether the detected relative position of the top unit electrode battery cell relative to the another unit electrode battery cell is within a predetermined range, wherein the control unit is further configured to remove the top unit electrode battery cell from the battery cell stack if the detected relative position is not within the predetermined range.

Description

Technical Field

[0001] This invention relates to an apparatus and method for manufacturing secondary battery modules.

[0002] More specifically, the present invention relates to apparatus and methods for manufacturing secondary battery modules with improved productivity. Background Technology

[0003] Secondary batteries (or rechargeable batteries) can be discharged through use and then restored to their original state through charging. They have recently been widely used as a power source for wireless devices such as personal digital devices, mobile phones, or laptops. Furthermore, secondary batteries have gained attention as a power source for electric vehicles, hybrid vehicles, and other vehicles considered a solution to the air pollution problems caused by the use of fossil fuels in traditional gasoline or diesel vehicles. Due to their significant advantages over other traditional energy sources, the applications of secondary batteries are continuously expanding, and consumer demand for them is increasing.

[0004] Among various rechargeable batteries, lithium rechargeable batteries are particularly widely used as energy sources for various electronic products because they exhibit high energy density, high operating voltage, and excellent storage and lifespan characteristics.

[0005] Meanwhile, secondary batteries can also be classified based on the structure of the electrode assembly consisting of a positive electrode, a separator, and a negative electrode. Typically, these assemblies fall into two categories: the first is a jelly roll (or wound) electrode assembly, in which long sheet-shaped positive and negative electrodes are wound together with a separator between them; the second is a stacked electrode assembly, in which multiple positive and negative electrodes of predetermined sizes are stacked sequentially one on top of the other with a separator inserted between them.

[0006] In the manufacturing process of stacked electrode assemblies, misalignment of electrodes during stacking can lead to undesirable problems. To prevent stacks of misaligned electrodes from moving to downstream processes, screening is performed. If a stack of misaligned electrodes is detected through screening, the entire stack is typically discarded. Therefore, electrode misalignment during stacking results in material waste and reduces the yield of secondary battery assemblies. Furthermore, it increases the total manufacturing time, negatively impacting the overall productivity of the manufacturing process.

[0007] Therefore, it would be beneficial to develop a technology that can solve the above-mentioned technical problems. Summary of the Invention

[0008] Technical issues

[0009] The object of this invention is to provide an apparatus and method for manufacturing secondary battery modules, which improves productivity and / or efficiency. This problem is addressed or alleviated, at least in part, by the subject matter of the independent claims, wherein further examples are included in the dependent claims.

[0010] Technical solution

[0011] One aspect of the present invention relates to an apparatus for manufacturing secondary battery assemblies. The apparatus may include: a first hopper configured to contain a plurality of single-electrode battery cells; a stacking platform configured to stack the plurality of single-electrode battery cells thereon to form a battery cell stack; a transfer unit configured to sequentially pick up a corresponding single-electrode battery cell from the plurality of single-electrode battery cells in the first hopper, move the corresponding single-electrode battery cell to the stacking platform, and place it one on top of the others; a detection unit configured to detect the relative position of the single-electrode battery cell placed on top of the battery cell stack relative to another single-electrode battery cell below it; and a control unit configured to determine whether the detected relative position of the top single-electrode battery cell relative to the other single-electrode battery cell is within a predetermined range, wherein the control unit is further configured to remove the top single-electrode battery cell from the battery cell stack if the detected relative position is not within the predetermined range.

[0012] The apparatus according to the invention can remove the misaligned individual electrode cell from the entire cell stack, including the misaligned electrode cell, instead of removing the entire cell stack. Therefore, the number of electrodes discarded can be reduced, preventing excessive material waste. Furthermore, since the remaining cell stack after removing the misaligned electrode can be used to manufacture electrode assemblies, the overall manufacturing time can be reduced.

[0013] A single-electrode battery cell can have a laminated structure comprising a positive electrode, a negative electrode, and / or a separator. However, the laminated structure of a single-electrode battery cell is not limited to this. A single-electrode battery cell can have different laminated electrode structures. For example, a single-electrode battery cell can be a type A dual-cell cell with a laminated structure comprising a positive electrode, a separator, a negative electrode, a separator, and a positive electrode, or a type C dual-cell cell with a laminated structure comprising a negative electrode, a separator, a positive electrode, a separator, and a negative electrode. A single-electrode battery cell can be a single-cell cell with a laminated structure comprising a positive electrode, a separator, a negative electrode, and a separator. A single-electrode battery cell can be a half-cell cell with a laminated structure comprising a separator, a negative electrode, and a separator. In a laminated structure, the electrodes and separator can be firmly bonded together by heat and pressure applied during or after the stacking process.

[0014] A battery cell stack can be formed by stacking multiple single battery cells. However, the invention is not limited to this. For example, half-cell cells or dual-cell cells can be used to form the battery cell stack, and an additional separator layer can be positioned between the dual-cell cells.

[0015] The first hopper can be any facility configured to accommodate the unit electrode battery cells. The stacking platform can be any facility with a flat surface on which the unit electrode battery cells can be stacked. The stacking platform may also include grippers or guide units to hold the battery cell stack while the top unit electrode battery cell is being separated from the battery cell stack.

[0016] The transfer unit can be configured to sequentially pick up a corresponding unit electrode battery cell from the plurality of unit electrode battery cells contained in a first hopper, move it to a stacking platform, and place it directly on the stacking platform, or, if a battery cell stack already exists on the stacking platform, place it on top of the battery cell stack. The transfer unit can be configured to pick up the unit electrode battery cell by applying a vacuum force. Placing the unit electrode battery cell should not affect the alignment of the other unit electrode battery cells forming the battery cell stack. The transfer unit may include one or more downward-facing vacuum holes facing the unit electrode battery cell. The vacuum holes may be located at the center of the transfer unit. A controller can control the position of the transfer unit such that the vacuum holes are located at the center of the unit electrode battery cell.

[0017] The detection unit can be configured to detect the relative position of one electrode cell with respect to another electrode cell. In other cases, the detection unit can detect the relative position between two cell electrodes.

[0018] In a single-electrode battery cell, the negative electrode is slightly larger than the positive electrode to ensure that the negative electrode completely covers the positive electrode below. This is often referred to as an overhang structure. In particular, in lithium-ion batteries, the overhang structure can reduce the risk of electrolyte decomposition or side reactions at the exposed edge of the positive electrode, which could otherwise lead to performance degradation or safety hazards.

[0019] Overhang structures can also be applied to battery cell stacks where multiple electrode cells are stacked one on top of another. However, due to differences in the size of the individual electrodes and inaccurate alignment of the electrode cells during the stacking process, electrode misalignment may occur. For example, misalignment between two electrode cells in a battery cell stack may result in the negative electrode of the upper electrode cell not adequately covering the positive electrode of the other electrode cell located directly below.

[0020] The control unit can determine whether the cell electrode cells previously added to the cell stack are misaligned based on a comparison between the detection results of the detection unit and a predetermined range. If a misalignment between cell electrode cells is identified, the control unit can control the transfer unit to remove the newest cell electrode cell located at the top of the cell stack.

[0021] According to an embodiment of the invention, the device may further include another transfer unit configured to pick up and move the top unit electrode battery cell from the battery cell stack and place it in a second hopper. Therefore, the invention can effectively remove misaligned unit electrode battery cells from the battery cell stack.

[0022] On the other hand, instead of equipping an additional transfer unit, the device of the present invention can use a transfer unit that moves the unit electrode cell between the first hopper and the stacking platform, which is also used to transfer the misaligned top unit electrode cell from the cell stack and place it in the second hopper. This simplifies the configuration of the device and reduces its overall size.

[0023] According to an embodiment of the present invention, the other transfer unit can be configured to pick up the cell electrode by applying a vacuum force.

[0024] Therefore, the present invention can pick up the top unit electrode cell without adversely affecting the alignment of the remaining unit electrode cells in the cell stack.

[0025] According to an embodiment of the present invention, the control unit can be configured to determine that the detected relative position is not within a predetermined range if, when viewed from the stacking direction, the negative electrode does not completely cover the positive electrode located directly below it.

[0026] Therefore, the present invention can reduce the risk of electrolyte decomposition or side reactions at the exposed edge of the positive electrode, which could otherwise lead to performance degradation or safety hazards.

[0027] According to an embodiment of the present invention, the detection unit may also be configured to detect the relative position of the first unit electrode cell with respect to the second unit electrode cell before placing the first unit electrode cell on top of the second unit electrode cell forming the cell stack.

[0028] According to an embodiment of the present invention, the control unit may be configured to: determine whether the detected relative position of the first unit electrode cell relative to the second unit electrode cell is within a predetermined range, and if the detected relative position is not within the predetermined range, control the stacking stage to move such that the relative position of the first unit electrode cell relative to the second unit electrode cell is within the predetermined range.

[0029] According to the present invention, if the detected relative positions are not within a predetermined range, the misalignment of the electrode cells can be easily adjusted by changing the positions of the individual electrode cells and / or the cell stack before stacking the electrode cells on the cell stack, so that their relative positions fall within the predetermined range. This can further reduce the amount of wasted electrodes and reduce manufacturing process time.

[0030] Another aspect of the present invention relates to a method for manufacturing a secondary battery assembly. The method may include: sequentially stacking a plurality of individual cell electrode modules, one on top of the other, to form a battery cell stack; detecting the relative position of the individual cell electrode module placed on top of the battery cell stack relative to another individual cell electrode module below it; determining whether the detected relative position of the top individual cell electrode module relative to the other individual cell electrode module is within a predetermined range; if the detected relative position is not within the predetermined range, removing the top individual cell electrode module from the battery cell stack; and continuing the sequential stacking steps after the removal step until a target number of individual cell electrode modules have been stacked.

[0031] Therefore, this invention enables the separate removal of misaligned individual electrode cells from other electrode cells forming the cell stack. This reduces wasted electrodes and saves overall process time.

[0032] According to an embodiment of the present invention, the method may further include transferring the removed unit electrode battery cell to a predetermined location and collecting it at the predetermined location.

[0033] Therefore, the present invention allows the collected, misaligned unit electrodes to be reused.

[0034] According to an embodiment of the present invention, when viewed from the stacking direction, if the anode placed above the cathode does not completely cover the cathode, it can be determined that the detected relative position is not within a predetermined range.

[0035] Therefore, the present invention can reduce the risk of electrolyte decomposition or side reactions at the exposed edge of the positive electrode, which could otherwise lead to performance degradation or safety hazards.

[0036] According to an embodiment of the present invention, the method may further include: detecting the relative position of the first unit electrode cell with respect to the second unit electrode cell before placing the first unit electrode cell on top of the second unit electrode cell forming the cell stack.

[0037] According to an embodiment of the present invention, the method may further include: determining whether the detected relative position of the first unit electrode battery cell relative to the second unit electrode battery cell is within a predetermined range; and if the detected relative position is not within the predetermined range, moving the battery cell stack including the second unit electrode battery cell to adjust the relative position of the first unit electrode battery cell relative to the second unit electrode battery cell to be within the predetermined range.

[0038] Beneficial effects of the present invention

[0039] According to the present invention, if the detected relative positions are not within a predetermined range, the misalignment of the electrode cells can be easily adjusted by changing the positions of the individual electrode cells and / or the cell stack before stacking the electrode cells on the cell stack, so that their relative positions fall within the predetermined range. This can further reduce the amount of wasted electrodes and reduce manufacturing process time.

[0040] When using the equipment or method according to the present invention to manufacture secondary battery components, improved efficiency of the manufacturing process can be achieved. Attached Figure Description

[0041] To gain a more complete understanding of the invention and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings. The invention will be explained in more detail below using exemplary embodiments specified in the schematic diagrams of the drawings, in which: Figure 1a and Figure 1b An exemplary battery cell stack having multiple unit electrode cells stacked sequentially in a vertical direction, according to the related art, is schematically shown. Figure 2 This is a flowchart illustrating a stacking process, including a monitoring step, according to relevant technologies; Figures 3a to 3c Various parts of an apparatus for manufacturing a secondary battery assembly according to an embodiment of the present invention are shown schematically. Figure 4 This is a flowchart illustrating a stacking process according to an embodiment of the present invention; and Figure 5 This illustrates an embodiment according to the present invention. Figure 4 A flowchart of the additional steps in the stacking process. Detailed Implementation

[0042] The terms or words used in this specification and claims should not be construed as having their ordinary or dictionary-based meanings, but should be interpreted in the broadest possible manner as having meanings and concepts consistent with the technical spirit of the invention.

[0043] In this disclosure, it should be understood that the terms “comprising,” “including,” “having,” etc., indicate the presence of the stated features, figures, steps, operations, elements, components, or combinations thereof, but do not exclude the presence or addition of one or more other features, figures, steps, operations, elements, components, or combinations thereof.

[0044] Furthermore, when a component (e.g., a layer, membrane, region, plate, etc.) is referred to as being "on" another component, this includes not only the case where the one component is "directly" on the other component, but also the case where another component is inserted between the two. Conversely, when a component (e.g., a layer, membrane, region, plate, etc.) is referred to as being "below" another component, this includes not only the case where the one component is "directly below" the other component, but also the case where another component is inserted between the two. Additionally, "arranged on..." in this disclosure can include both arrangements at the lower and upper parts.

[0045] Various components may be described using terms such as "first" and "second," but these components should not be limited by these terms. These terms are used only for the purpose of distinguishing one component from another. For example, a first component may be referred to as a second component without departing from the scope of the invention, and similarly, a second component may be referred to as a first component. Unless the context clearly indicates otherwise, singular expressions include plural expressions.

[0046] Furthermore, the same reference numerals will be used throughout all the accompanying drawings to refer to parts that perform similar functions or operations. In this disclosure, when one part is said to be connected to another, this means not only that the one part can be directly connected to the other part, but also that the one part can be indirectly connected to the other part via other parts. Moreover, including an element does not mean excluding other elements, but rather means that, unless otherwise specified, such elements may also be included.

[0047] In the following description, a system and method for manufacturing a secondary battery assembly according to the present invention will be described in detail with reference to the accompanying drawings.

[0048] A secondary battery assembly can consist of a positive electrode, a separator, and a negative electrode.

[0049] The positive and negative electrodes can be manufactured as sheets. The electrode sheets can have a structure in which an electrode mixture layer is coated on one or both sides of the current collector layer.

[0050] The electrode mixture layer can be a slurry containing active materials, a binder, and a solvent, where the binder helps to hold the active material particles together and adhere them to the current collector layer. Active materials are components that undergo electrochemical reactions during charge and discharge cycles in a secondary battery to store and release energy. For example, one or more of lithium cobalt oxide, lithium manganese oxide, lithium iron phosphate, nickel manganese, and nickel cobalt aluminum oxide can be used as positive electrode active materials. For example, one or more of graphite, lithium titanate, and silicon-based materials can be used as negative electrode active materials.

[0051] The current collector layer can be a thin metal foil designed to conduct current between the electrochemical active material and the external circuitry of the battery. For example, an aluminum layer can be used for the positive electrode current collector, while a copper layer can be used for the negative electrode current collector. Additional coatings can be applied to the current collector layer to improve adhesion to the active material, enhance corrosion resistance, or reduce resistance.

[0052] An electrode mixture layer can be coated onto the current collector layer to a desired thickness in a desired area. The coated portion can be positioned in the middle of the electrode sheet along its width, and uncoated portions can be positioned, for example, on either side of the coated portion. Various methods can be used in the coating process. For example, the slurry can be uniformly spread on the surface of the current collector layer using a doctor blade. The slurry can be extruded onto the moving current collector layer using a slit die. The current collector can be immersed in the slurry and then removed at a controlled speed. In other cases, the slurry can be atomized and sprayed onto the current collector.

[0053] After coating the electrode mixture layer onto the current collector layer, a process is performed to increase the density of the coated electrode mixture layer, commonly referred to as a drying and extrusion process. This process reduces the thickness of the electrode sheet to achieve the desired density, which enhances the energy density and mechanical integrity of the electrode sheet. For example, a heavy roller with a heater can be used to extrude the electrode sheet. During this process, pressure is applied to the electrode sheet through the heavy roller.

[0054] The separator is made of a thin, porous material. It serves to physically isolate the positive and negative electrodes from each other while allowing ions to flow between them. The separator prevents short circuits, allows ion flow, and ensures mechanical stability by supporting the electrode assembly, thus helping to maintain the integrity of the battery's internal structure during operation. The separator material needs to be chemically stable, mechanically strong, and low-cost. It may also need a relatively low melting point, which can provide a safety mechanism by stopping the battery from operating if it overheats. For example, thin polypropylene (PP) layers, thin ceramic-coated separator layers, nonwoven fabric layers, or composite layers made of different materials (e.g., polymers and ceramics) can be used to optimize performance characteristics such as mechanical strength, thermal stability, and electrolyte wettability. The choice of separator depends on the specific requirements of the secondary battery specifications.

[0055] Simultaneously, the dried electrode sheets and separator are cut. The dried electrode sheets are cut into the desired precise shape and size required by the final battery assembly specifications. The separator is also cut into the predetermined shape and size to meet the specifications.

[0056] A punching process can also be performed on the uncoated areas of the electrode sheet to form electrode tabs. During the punching process, portions of the electrode sheet without the electrode mixture coating are selectively removed or cut away, thus creating electrode tabs. This process can be accomplished, for example, using precision tools such as lasers or mechanical molds. The electrode tabs, which form the uncoated areas of the current collector layer, can be electrically connected to external electrode leads. The electrode leads can be metal strips that connect the electrode assembly to external battery terminals via the electrode tabs. The electrode tabs can be formed into specific patterns, such as rectangular, U-shaped, or V-shaped cuts, to optimize attachment to the electrode leads and ensure a good electrical connection.

[0057] The prepared positive electrode, separator, and negative electrode are stacked alternately in a precise order to construct an electrode assembly. In other cases, a single-cell electrode with a layered structure can be obtained by stacking, where each positive and negative electrode is separated by a separator inserted between them. Subsequently, an electrode assembly can be constructed by stacking multiple single-cell electrode units instead of individual electrodes.

[0058] A single-electrode battery cell can have a laminated structure comprising a positive electrode, a negative electrode, and / or a separator. However, the laminated structure of a single-electrode battery cell is not limited to this. A single-electrode battery cell can have different structures. For example, a single-electrode battery cell can be a type A dual-cell cell with a laminated structure comprising a positive electrode, a separator, a negative electrode, a separator, and a positive electrode, or a type C dual-cell cell with a laminated structure comprising a negative electrode, a separator, a positive electrode, a separator, and a negative electrode. A single-electrode battery cell can be a single-cell cell with a laminated structure comprising a positive electrode, a separator, a negative electrode, and a separator. A single-electrode battery cell can also be a half-cell cell with a laminated structure comprising a separator, a negative electrode, and a separator.

[0059] In a laminated structure, electrodes and diaphragms are firmly bonded together by heat and pressure applied during or after the stacking process.

[0060] Figure 1a and Figure 1b An exemplary battery cell stack 20, 30, according to the related art, is shown having a plurality of unit electrode battery cells 10a, 10b, 10c, 10d stacked sequentially in the vertical direction.

[0061] Referring to Figure 1, each unit electrode cell 10a, 10b, 10c, and 10d can be a single cell comprising a separator 12b, a negative electrode 13, a separator 12a, and a positive electrode 11 stacked sequentially from bottom to top. However, this embodiment is not limited to this. The unit electrode cell can be any other structure, particularly including dual-cell cells, half-cell cells, full-cell cells, or any combination thereof.

[0062] Exemplary single-electrode battery cells 10a, 10b, 10c, 10d and their respective components typically have length, width, and height. Height (or, in other words, thickness) can be a measure along the stacking direction of the respective components including electrodes 11, 13 and separators 12a, 12b. Length is the extensional dimension along the direction in which the electrode tabs protrude from the body of the single-electrode battery cell 10a, 10b, 10c, 10d, perpendicular to the height. Width is a measure along a direction perpendicular to both height and length.

[0063] In the exemplary single-electrode battery cells 10a, 10b, 10c, and 10d, the negative electrode 13 may be slightly larger than the positive electrode 11 in width. Therefore, the battery cell stacks 20 and 30 have a so-called overhang structure in the sense that the positive electrode 11 is completely covered by the overhang of the negative electrode 13. In particular, the overhang structure can be advantageous in lithium-ion batteries because it reduces the risk of electrolyte decomposition or side reactions at the exposed edges of the positive electrode, which could otherwise lead to performance degradation or safety hazards.

[0064] During the stacking of these unit electrode battery cells 10a, 10b, 10c, and 10d to construct battery cell stacks 20 and 30, misalignment may occur. For example, as... Figure 1b As shown, the battery cell stack 30 may include a misaligned unit electrode battery cell 10b, as well as other unit electrodes 10a, 10c and 10d.

[0065] To prevent defective cell stacks 30 with misaligned cell electrodes 10b from being transferred downstream during manufacturing, a dimensional monitoring process can be performed during the stacking process.

[0066] Figure 2 This is a flowchart illustrating the stacking process, including the monitoring step.

[0067] refer to Figure 2A method for manufacturing secondary batteries involves sequentially stacking multiple individual cell electrode units on top of each other to form a battery cell stack. Specifically, in step S1, an individual cell electrode unit is stacked on top of a previously constructed partial battery cell stack. After stacking this additional individual cell electrode unit, in step S2, the relative position of the individual cell electrode unit placed on top of the battery cell stack relative to the individual cell electrode unit directly below it is detected. Based on the detected relative position, in step S3, it is determined whether the detected relative position of the top individual cell electrode unit relative to the individual cell electrode unit directly below it is within a predetermined range. If it is determined that the detected relative position of the top individual cell electrode unit relative to the individual cell electrode unit directly below it is within the predetermined range, the sequential stacking step S1 continues until the battery cell stack includes a target number of individual cell electrode units. If it is determined that the detected relative position falls outside the predetermined range, the battery cell stack can be identified as defective or misaligned.

[0068] Figure 3a , Figure 3b and Figure 3c Various parts of an apparatus for manufacturing a secondary battery assembly according to an embodiment of the present invention are illustrated schematically.

[0069] Manufacturing equipment 100 may be equipped with a first hopper 110 configured to hold a plurality of individual battery cells. However, this embodiment is not limited thereto. Any other means may be used to hold the plurality of individual battery cells 10 prior to supplying them to the stacking process. For example, instead of the first hopper 110, a conveyor (not shown) may be used to supply the individual battery cells 10 to the stacking process. With this arrangement, the plurality of individual battery cells 10 can be conveyed simultaneously while being arranged sequentially on the conveyor.

[0070] The device 100 may further include a stacking platform 120 configured to allow multiple unit electrode battery cells 10 to be stacked thereon, thereby forming a battery cell stack 40. The device 100 may also include a transfer unit 130 configured to pick up a corresponding unit electrode battery cell 10e from the plurality of unit electrode battery cells housed in the first hopper 110 and move it to the stacking platform 120. The transfer unit 130 may be configured to pick up the unit electrode battery cell 10e by applying a vacuum force. The transfer unit 130 may include one or more downward-facing vacuum holes (not shown) facing the unit electrode battery cell housed in the first hopper 110. The vacuum hole is preferably located at the center of the transfer unit 130. The control unit 150 may control the position of the transfer unit 130 such that the vacuum hole can be positioned at the center of the unit electrode battery cell 10e to be picked up. By applying a vacuum force, the unit electrode cell 10e located at the top can be picked up in a stable manner by the transfer unit 130, thereby minimizing the impact on the other unit electrodes remaining in the first hopper 110. Subsequently, the transfer unit 130 moves the picked-up unit electrode cell 10e to the stacking platform 120. Upon reaching the stacking platform 120, the transfer unit 130 places the single unit electrode cell 10e on top of the existing cell stack 40, or more specifically, on the unit electrode cell 10f that was last added to the cell stack 40 and located at the top.

[0071] The device 100 may further include a detection unit 140 configured to detect the relative position of a single-electrode battery cell 10e placed on top of the battery cell stack 40 relative to a single-electrode battery cell 10f directly below it. Once the relative position is detected, the control unit 150 determines whether the detected relative position of the top single-electrode battery cell 10e relative to the single-electrode battery cell 10f directly below it is within a predetermined range. For example, the control unit 150 may determine whether the positive electrode of the previously stacked single-electrode battery cell 10f is completely below the overhang of the negative electrode of the currently stacked single-electrode battery cell 10e. For this purpose, the two lateral sides of the negative electrode of the single-electrode battery cell 10e can be detected by the detection unit 130, and the vertical extensions of these two lateral sides can be identified as line A and line A', respectively. See [reference needed]. Figure 3bThe control unit 150 can be configured to determine that, when viewed from the stacking direction of the electrode cells, if the anode (negative electrode) does not completely cover the cathode (positive electrode) located directly below it, the detected relative position is outside a predetermined range. For example, if a portion of the positive electrode of cell 10f extends beyond the area covered by the negative electrode of cell 10e, or in other words, beyond lines A and A', cell 10e should be identified as misaligned.

[0072] Alternatively or additionally, the detection unit 140 can be configured to measure distances D1 and D2, respectively, between lines A and A' and the center line C of the stack 120. The control unit 150 can be configured to determine whether either distance D1 or distance D2 is greater than a reference (threshold) value. This reference value can be determined based on the specifications of the battery assembly. Furthermore, distances D1 and D2 may not be the same. For example, they may have different values ​​if the center line of the tested cell electrode is not precisely aligned with the center line C of the stack 120. According to this method, the misalignment of the top cell electrode 10e can be determined by detecting the absolute position of the top cell electrode 10e, without considering its relative position to the cell electrode 10f below.

[0073] If the relative position of the detected top-positioned cell electrode 10e with respect to the cell electrode 10e directly below it is outside a predetermined range and / or if either distance D1 or D2 is greater than a reference value, the cell electrode 10e is identified as misaligned. The control unit 150 can be programmed to remove the identified misaligned top-positioned cell electrode 10e from the cell stack 40.

[0074] The top unit electrode cell 10e that has been identified as misaligned can be removed by the second transfer unit 170. The second transfer unit 170 is configured to pick up the top unit electrode cell 10e separately from the other electrode cells forming the cell stack 40, and move and place it in the second hopper 160.

[0075] The second transfer unit 170 can be configured to pick up individual cell electrode units by applying a vacuum force. Picking up the top cell electrode unit 10e should not affect the alignment of the remaining individual cell electrode units in the cell stack 40. The second transfer unit 170 may include one or more downward-facing vacuum holes (not shown) facing the top cell electrode unit 10e. The vacuum holes may be located at the center of the second transfer unit 170. The control unit 150 can control the position of the second transfer unit 170 such that the vacuum holes are positioned at the center of the top cell electrode unit 10e.

[0076] Optionally, the stacking platform 120 may also include a clamp or guide unit (not shown) to hold the battery cell stack 40 while the misaligned top cell electrode 10e is separated from the battery cell stack 40 by the second transfer unit 170. This can further reduce any undesirable effects that the second transfer unit 170 may exert on the other electrodes of the battery cell stack 40.

[0077] The cell electrode 10e removed by the second transfer unit 170 can be transferred to a designated space and collected there.

[0078] Therefore, the device 100 can remove the misaligned single-electrode battery cell 10e separately from the entire battery cell stack 40, instead of discarding the entire battery cell stack 40. This reduces the number of discarded electrodes and prevents excessive material waste. Furthermore, since the remaining battery cell stack 40 after removing the misaligned top single-electrode 10e can be used to manufacture electrode assemblies, the overall manufacturing time can be reduced.

[0079] By improving the placement accuracy of the individual battery cells on top of the battery cell stack, wasted electrodes can be further reduced. The accuracy of pickup and placement by the transfer unit 130 can be improved by using the detection unit 140 and the control unit 150. For example, when the transfer unit 130 holding the individual battery cells has arrived at the stacking platform 120, the relative position of the individual battery cells 10e and the battery cell stack 40 can be detected before placing the individual battery cells 10e on top of the battery cell stack 40. Based on the detection result, the control unit 150 can determine whether the relative position is within a predetermined range. If the detected relative position is not within the predetermined range, the control unit 150 can adjust the relative position by moving at least one of the individual battery cells 10e and the battery cell stack 40 so that their relative position enters the predetermined range.

[0080] Figure 4 and Figure 5 This is a flowchart illustrating a stacking process that includes a removal step and a moving step, according to an embodiment of the present invention.

[0081] refer to Figure 4A method for manufacturing secondary batteries involves sequentially stacking multiple unit electrode battery cells, one on top of the other, to form a battery cell stack. Specifically, in step S1, a unit electrode battery cell is stacked on top of a previously constructed partial battery cell stack. After stacking this additional unit electrode battery cell, in step S2, the relative position of the unit electrode battery cell placed on top of the battery cell stack relative to the unit electrode battery cell directly below it is detected. Based on the detected relative position, in step S3, it is determined whether the top unit electrode battery cell is within a predetermined range relative to the unit electrode battery cell directly below it. Specifically, when viewed from above, if the anode (negative electrode) placed above the cathode (positive electrode) along the stacking direction does not completely cover the cathode, it can be determined that the detected relative position is not within the predetermined range. If it is determined that the detected relative position of the top unit electrode battery cell relative to the unit electrode battery cell directly below it is within the predetermined range, the sequential stacking step S1 continues until the battery cell stack includes a target number of unit electrode battery cells. If it is determined that the detected relative position falls outside the predetermined range, the top unit electrode battery cell can be identified as misaligned. In step S4, the misaligned top cell electrode can be removed, and the process returns to step S1.

[0082] At the same time, refer to Figure 5 Method 200 may further include additional steps, which may optionally be performed before step S1. Preferably, these additional steps are performed once the transfer unit 130 holding the unit electrode battery cell has reached the stacking stage 120, before placing the unit electrode battery cell on top of another unit electrode battery cell forming the battery cell stack. In step S0-1, the relative position of the unit electrode battery cell with respect to the top unit electrode battery cell forming the battery cell stack is detected. Based on this detection, in step S0-2, it is determined whether the relative position of the unit electrode battery cell with respect to the top unit electrode battery cell of the battery cell stack is within a predetermined range. If the detected relative position of the unit electrode battery cell with respect to the top unit electrode battery cell of the battery cell stack is determined to be within the predetermined range, the process proceeds directly to step S1. If it is determined that the detected relative position falls outside the predetermined range, the relative position is adjusted to enter the predetermined range, for example, by moving the unit electrode battery cell and / or the battery cell stack (S0-3). Subsequently, the process proceeds to step S1.

[0083] While specific embodiments have been shown and described herein, those skilled in the art will understand that a variety of alternative and / or equivalent implementations exist. It should be understood that the exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing overview and detailed description will provide those skilled in the art with a convenient roadmap for implementing at least one exemplary embodiment, and it should be understood that various changes can be made to the function and arrangement of the elements described in the exemplary embodiments without departing from the scope set forth in the appended claims. Generally, this application is intended to cover any modifications or variations of the specific embodiments discussed herein.

[0084] (List of reference numerals in the attached diagram)

[0085] 10a, 10b, 10c, 10d, 10e, 10f single-electrode battery cells

[0086] 11 Positive electrode

[0087] 12a, 12b diaphragms

[0088] 13 Negative electrode

[0089] 20, 30, and 40 cell stacks

[0090] 100 devices

[0091] 110 First Hopper

[0092] 120 stacking platform

[0093] 130 transfer units

[0094] 140 detection units

[0095] 150 control unit

[0096] 160 Second Hopper

[0097] 170 Second Transfer Unit

Claims

1. An apparatus for manufacturing secondary battery modules, comprising: The first hopper is configured to hold multiple unit electrode battery cells; A stacking platform, the stacking platform being configured to stack the plurality of unit electrode battery cells on the stacking platform to form a battery cell stack; A transfer unit is configured to sequentially pick up a corresponding one of the plurality of unit electrode battery cells in the first hopper, move the corresponding one unit electrode battery cell to the stacking platform and place it on top of the others in such a manner. A detection unit is configured to detect the relative position of a cell electrode placed on top of the cell stack with respect to another cell electrode below it. as well as A control unit configured to determine whether the detected relative position of the top unit electrode cell relative to the other unit electrode cell is within a predetermined range. The control unit is further configured to remove the top unit electrode battery cell from the battery cell stack if the detected relative position is not within the predetermined range.

2. The device of claim 1 further includes another transfer unit configured to pick up and move the top unit electrode battery cell from the stack and place the top unit electrode battery cell in a second hopper.

3. The device according to claim 2, wherein, The other transfer unit is configured to pick up the cell electrode battery cells by applying a vacuum force.

4. The device according to any one of the preceding claims, wherein, The control unit is configured to determine that the detected relative position is not within the predetermined range if, when viewed from the stacking direction, the anode placed above the cathode does not completely cover the cathode.

5. The device according to any one of the preceding claims, wherein, The detection unit is further configured to detect the relative position of the first unit electrode cell with respect to the second unit electrode cell before placing the first unit electrode cell on top of the second unit electrode cell forming the cell stack.

6. The device according to claim 5, wherein, The control unit is configured to: Determine whether the detected relative position of the first unit electrode cell relative to the second unit electrode cell is within a predetermined range, and If the detected relative position is not within the predetermined range, the stacking stage is controlled to move so that the relative position of the first cell electrode relative to the second cell electrode is within the predetermined range.

7. A method for manufacturing a secondary battery assembly, comprising: Multiple individual battery cells are stacked sequentially, one on top of the other, to form a battery cell stack. Detect the relative position of a unit electrode cell placed on top of the battery cell stack with respect to another unit electrode cell below it; Determine whether the detected relative position of the top unit electrode cell relative to the other unit electrode cell is within a predetermined range; If the detected relative position is not within the predetermined range, the top unit electrode cell is removed from the cell stack. as well as After the removal step, the stacking steps continue sequentially until the target number of cell electrode units are stacked.

8. The method of claim 7 further comprises transferring the removed unit electrode cell to a predetermined location and collecting it at the predetermined location.

9. The method according to claim 7 or 8, wherein, When viewed from the stacking direction, if the anode placed above the cathode does not completely cover the cathode, it is determined that the detected relative position is not within the predetermined range.

10. The method according to any one of claims 7 to 9, further comprising: Before placing the first unit electrode cell on top of the second unit electrode cell forming the cell stack, the relative position of the first unit electrode cell with respect to the second unit electrode cell is detected.

11. The method of claim 10, further comprising: Determine whether the detected relative position of the first unit electrode cell relative to the second unit electrode cell is within a predetermined range; as well as If the detected relative position is not within the predetermined range, the stack of battery cells including the second unit electrode battery cell is moved to adjust the relative position of the first unit electrode battery cell relative to the second unit electrode battery cell to the predetermined range.

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