System and method for battery stacking and slitting film material

Abstract

The present disclosure relates to a system for transferring and stacking electrodes in a battery stacking system. The system includes a slitting device having a buffer device that feeds the slit electrodes to a feed conveyor that transports the slit electrodes to a transport device with vacuum assisted gripping boots. The transport device transfers the electrodes from the feed conveyor to a pick-up device equipped with gripping boots to pick up the battery material and place the battery material in a stack on a stacking platform.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit and priority of U.S. Application Serial No. 63 / 615,017, filed December 27, 2023; U.S. Application Serial No. 63 / 615,013, filed December 27, 2023; and U.S. Application Serial No. 63 / 615,009, filed December 27, 2023, the contents of each of which are incorporated herein by reference in their entirety.

[0003] Copyright Notice

[0004] This patent application contains material protected by copyright. The copyright holder does not object to any fax reproduction of this patent document or patent disclosure (as it appears in the U.S. Patent and Trademark Office), but otherwise retains all other copyrights. Technical Field

[0005] This disclosure generally relates to methods, systems, and apparatus for battery stacking. It includes systems and methods for slitting thin-film materials, in other words, systems and methods for cutting thin-film materials from webs or rolls into discrete pieces, wherein the thin-film material is a separator material used in battery manufacturing. Background Technology

[0006] Prismatic batteries are formed by alternating layers of staggered cathodes, thin film material in the form of an insulating separator, and anodes. To avoid malfunctions, there should be no electrical contact between the anodes and adjacent cathodes. Therefore, to form a battery stack, the separator material is a layer located between the alternating anode and cathode layers.

[0007] There are different methods to achieve a battery stack with an anode, a cathode, and a separator between the anode and cathode. One method is to fold the separator back and forth between alternating anode and cathode layers, a technique known as Z-folding.

[0008] Manufacturing battery stacks involves many different apparatus and methodological steps. Improving the speed of the manufacturing process would be beneficial, but achieving this requires improvements in multiple aspects of both the systems and methods used.

[0009] Another approach is to cut the diaphragm material into discrete sheets and laminate them, placing one sheet between each layer of anode and cathode. Diaphragms are typically made of very thin and flexible materials, which, without lamination or subjecting them to another similar process, would make them difficult to manipulate without deformation or other adverse effects. However, the lamination process adds an extra step, making the overall manufacturing process more complex.

[0010] Battery stacking is a key process in modern battery manufacturing, involving the arrangement of multiple battery cells to form a complete module or battery pack. Battery cells can be cylindrical, prismatic, or pouch-shaped, and they are stacked in layers of alternating anode and cathode layers separated by an insulating separator. This stacking process aims to increase the energy density and power capacity of battery systems, making it a critical technology for applications such as electric vehicles, grid storage, and portable electronics. The stacking process must ensure consistent alignment and minimal spacing to avoid performance loss or safety risks due to short circuits or thermal events.

[0011] In battery stacking processes, automated systems are typically used to manipulate the precise placement of electrodes and separators. A key challenge in battery stacking manufacturing is maintaining high throughput while ensuring precise alignment of each layer. This is particularly important for high-performance batteries, such as those employing lithium-ion chemistry, where even slight misalignment can affect electrochemical performance and cycle life. Innovations in automation and robotics, such as laser alignment and machine vision systems, are increasingly being used to improve the accuracy and speed of stacking processes. This not only increases production efficiency but also significantly reduces the cost of high-volume battery manufacturing, painting a rosy picture for the industry's future.

[0012] Another essential consideration in battery stacking manufacturing is the need for effective quality control. As batteries achieve higher energy densities and are used in safety-critical applications such as electric vehicles, the quality and consistency of the stacking process must be monitored in real time. Techniques such as X-ray inspection and impedance spectroscopy analysis detect defects such as misaligned cells or foreign particles, which can lead to performance degradation or safety issues. With the continued growth in demand for higher capacity batteries, further advancements in automation, material manipulation, and defect detection technologies are crucial for scaling up battery stacking manufacturing while maintaining stringent safety and performance standards.

[0013] While Z-folded batteries offer higher energy density through vertically stacked cells, they also present several limitations and challenges. One major issue is the difficulty in ensuring precise alignment between multiple layers, as any misalignment can lead to uneven pressure distribution, causing mechanical stress on the electrodes and separator. This can result in performance degradation, internal short circuits, or even thermal runaway in extreme cases. Because Z-folding requires continuous lateral shifting of the separator web during lamination to fold it to the next layer, visually inspecting the stack's precision and minimizing excess electrode and separator material to prevent these mechanical problems is difficult and expensive. The significant material wastage per stack also contributes to the high manufacturing cost.

[0014] Another challenge is heat dissipation; with cells tightly stacked together, heat can accumulate within the battery pack, increasing the risk of overheating and shortening the overall battery life. Furthermore, the complexity of automated stacking processes, particularly for thin and flexible components such as the separator in lithium-ion batteries, can lead to manufacturing defects if not carefully controlled. These limitations underscore the need for advanced manufacturing technologies and stringent quality control measures to ensure the safety and reliability of Z-type stacked batteries in demanding applications such as electric vehicles and energy storage systems.

[0015] What would be beneficial is the ability to better manipulate the separator material in battery production. Therefore, there is often a need for improvements when it comes to battery manufacturing, especially when it comes to the manipulation of separator materials.

[0016] Therefore, what is lacking in current battery stacking systems is a battery stacking system and method that incorporates more advanced alignment technologies and real-time quality control methods, which can ensure higher accuracy and significantly reduce manufacturing defects compared to conventional Z-folding systems. It would be beneficial to increase the speed of the manufacturing process, but achieving this requires improvements in several different aspects of both the system and the method used. Summary of the Invention

[0017] This summary is provided to introduce, in a simplified form, the concept options further described in the detailed description of this disclosure. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended to define the scope of the claimed subject matter.

[0018] This disclosure aims to provide improved systems and methods for battery stacking, and in particular improved systems and methods for manufacturing prismatic batteries comprising an anode layer, a cathode layer, and a separator material layer. One objective is to provide systems and methods that are faster than those currently available.

[0019] The object of this invention is to solve at least some of the aforementioned problems and issues. The object of embodiments of this invention is to provide an apparatus for slitting thin film materials, particularly an apparatus for slitting separator materials used in battery manufacturing.

[0020] The object of embodiments of the present invention is to provide a buffer device for receiving thin film material at a constant speed and outputting the thin film material at a variable speed. In some embodiments, the output is accomplished in a motion including rapid acceleration, rapid deceleration, and complete stop. Another object is to enable high-speed manufacturing, such as high-speed battery manufacturing.

[0021] The first aspect of this disclosure generally relates to a system for stacking diced electrodes in a battery stack. The system includes: a first dicing device having at least three faces, a cutting device, and a first buffer device, wherein the first dicing device is configured to dice electrodes from a thin film material; a second dicing device having at least three faces, a cutting device, and a second buffer device, wherein the first dicing device is configured to dice electrodes from the thin film material; a third dicing device having at least three faces, a cutting device, and a third buffer device, wherein the first dicing device is configured to dice electrodes from the thin film material; a first feed conveyor configured to transport the diced electrodes from the first dicing device to a first nest; a second feed conveyor configured to transport the diced electrodes from the second dicing device to a second nest; and a third feed conveyor configured to transport diced separator sheets from the third dicing device to a third nest. A conveying device having at least one vacuum-assisted gripping shoe, wherein the conveying device is configured to use the at least one vacuum-assisted gripping shoe to transfer anodes, cathodes, and separators from each of a first, second, and third feed conveyor, respectively, to a pickup device; wherein the pickup device is further configured to pick up anodes, cathodes, and separators from the at least one vacuum-assisted gripping shoe of the conveying device using one of at least three gripping shoes coupled to the pickup device; at least one battery stacking station adapted to receive at least one diced anode, at least one diced cathode, and at least one diced separator material; wherein the at least one battery stacking station is adapted to be positioned at a battery stacking position and a battery removal position; and a removal device adapted to remove a battery stack from the at least one battery stacking station when the battery stacking station is in the battery removal position.

[0022] In some embodiments, the conveying device is adapted to alternately transfer the anode and cathode to the rotary pickup device.

[0023] In some embodiments, the conveying device has a position where the conveying device simultaneously grasps the anode and releases the cathode, and a position where the conveying device simultaneously grasps the cathode and releases the anode.

[0024] In some embodiments, the system further includes a quality inspection device adapted to inspect the cathode, the diaphragm, and the anode before they are transferred to the first, second, and third nests.

[0025] In some embodiments, the system further includes a quality inspection device adapted to inspect the cathode, the diaphragm, and the anode before they are transferred to the pickup device.

[0026] In some embodiments, each of the first, second, and third nests further includes an alignment device configured to align the electrodes and the diaphragm.

[0027] In some embodiments, the delivery device includes an alignment device configured to align the electrodes and the diaphragm.

[0028] In some embodiments, each of the first, second, and third nests further includes an air bearing on which the electrode is positioned.

[0029] In some embodiments, the system further includes a second battery stacking station.

[0030] In some embodiments, the first battery stacking station and the second battery stacking station further include a vacuum source fluidly coupled to the first battery stacking station and the second battery stacking station, wherein the vacuum source is adapted to apply a suction force around the battery stack.

[0031] In some embodiments, each battery stack station is positioned on a mechanical conveying device and is thus adapted to move along at least two axes perpendicular to each other.

[0032] In some embodiments, each battery stacking station includes a movable sidewall.

[0033] In some embodiments, the first, second, and third buffer devices are adapted to output a predetermined length of thin film material in a graduated motion manner, the graduated motion including rapid acceleration followed by rapid deceleration.

[0034] In some embodiments, the first, second, and third buffer devices further include suction plates, the suction plates including a vacuum source adapted to pull thin film material toward the suction plates.

[0035] In some embodiments, the first, second, and third buffer devices further include measuring devices for determining the position of the thin film material.

[0036] In some embodiments, the first, second, and third slitting devices provide indexing motion, which includes complete cessation of the film material and cutting of the film material during the cessation.

[0037] In some embodiments, the first, second, and third slitting devices are used, wherein a film material is attached to at least three surfaces of the first, second, and third slitting devices using suction.

[0038] In some embodiments, the first, second, and third slitting devices are configured to apply different amounts of suction to each of the at least three surfaces.

[0039] In some embodiments, the cutting device of the first, second, and third slitting devices is a blade.

[0040] Another aspect of this disclosure generally relates to a system for transferring electrodes in a battery stacking system. The system includes a first conveying device for transferring an anode and a second conveying device for transferring a cathode, a first nest for receiving an anode and a second nest for receiving a cathode, and a gripping device adapted to alternately transfer the anode and cathode from their respective nests to subsequent stations in the system.

[0041] According to another aspect, a system for transferring electrodes to a battery stack is provided. The system includes: a pickup device comprising a surface adapted to attach electrodes to its surface by means of a vacuum, wherein the surface has a plurality of individually controllable vacuum zones; and a processing device for each vacuum zone, wherein each processing device is adapted to track its corresponding vacuum zone. The system also includes a computing device associated with the pickup device, the computing device being adapted to monitor the position of each vacuum zone and transmit the position to the processing device. When a vacuum zone has reached a predetermined position, the processing device is adapted to shut off its corresponding vacuum zone.

[0042] According to another aspect, a system for battery stacking is provided. The system includes: a first battery stacking station adapted to receive anode, cathode, and separator materials; and a second battery stacking station adapted to receive anode, cathode, and separator materials. Each of the battery stacking stations is adapted to be positioned at a battery stacking location and a battery removal location. The system also includes a removal device adapted to remove the battery stack from the battery stacking station when the battery stack is in the battery removal location.

[0043] According to another aspect, a method for stacking and removing batteries is provided. The method includes: stacking anode, cathode, and separator materials on a first battery stacking station at a stacking position until a first battery stack has been formed; moving the first battery stacking station to a removal position; and moving a second battery stacking station to a stacking position. The method further includes: stacking anode, cathode, and separator materials on a second battery stacking station until a second battery stack has been formed, and removing the first battery stack from the first battery stacking station.

[0044] According to one aspect, a slitting apparatus is provided for cutting thin film material into parts. The apparatus includes a body comprising at least two substantially flat surfaces for receiving thin film material, wherein each surface is adapted to attach the thin film material to that surface, and wherein the body is adapted to rotate about an axis. The slitting apparatus further includes a cutting device comprising a cutting blade adapted to cut the thin film material when it is attached to one of the at least two surfaces of the body. The body is adapted to rotate in a manner including an indexing motion of initial acceleration followed by deceleration, and the cutting device is adapted to cut the thin film material during the indexing motion.

[0045] According to another aspect, a system for separating and cutting a film into parts is provided. The system includes a slitting device according to the first aspect and a buffer device for transferring film material to the slitting device, wherein the buffer device is adapted to receive the film material at a constant speed and output it to the slitting device at a variable speed.

[0046] According to another aspect, a method for cutting a thin film material into parts is provided. The method includes transferring the thin film material to the face of a slitting apparatus, the slitting apparatus comprising a body having at least two substantially flat faces for receiving the thin film material, each face being adapted to attach the thin film material to that face, wherein the body is adapted to rotate about an axis. The method further includes rotating the body in a manner including an indexing motion of initial acceleration followed by deceleration, thereby transferring the thin film material from a first position to a second position. The method further includes cutting the thin film material while it is attached to one of the at least two faces of the body.

[0047] According to one aspect, a buffer device is provided, adapted to receive film material at a constant speed and output film material at a variable speed. The buffer device includes a first conveying section adapted to convey and receive film material at a constant speed. The buffer device also includes a second conveying section adapted to convey and output film material at a variable speed, wherein the variable speed has a maximum speed higher than the constant speed and a minimum speed lower than the constant speed. The buffer device further includes a buffer section located between the first and second conveying sections for accommodating the film material.

[0048] According to another aspect, a system for transferring thin film material is provided. The system includes a buffer device as disclosed herein and a film dispensing device for providing the thin film material at a constant rate. The system also includes a film extraction device adapted to extract the thin film material from the buffer device at a variable rate.

[0049] According to another aspect, a method is provided for transferring film material from a film dispensing device that provides film material at a constant speed to a film extraction device that extracts film material at a variable speed. The method includes feeding film material to a buffer device at a constant speed and receiving film material at the buffer device. The method further includes providing film material to a buffer section of the buffer device until the amount of film material at the buffer section is at least the amount required for one film extraction operation. The method also includes extracting a certain amount of film material from the buffer device during the film extraction operation such that the amount of film material extracted from the buffer section is equal to the amount of film extracted by the film extraction device in one extraction operation, thereby reducing the amount of film material in the buffer section, said film extraction operation including initial acceleration followed by deceleration.

[0050] In one embodiment, the battery stacking system includes a rotary transfer device adapted to alternately transfer anodes and cathodes to a rotary pickup prism.

[0051] In one embodiment, the battery stacking system includes a quality inspection device adapted to inspect the cathode, the separator, and the anode before they are transferred to a rotary transfer device.

[0052] In one embodiment, the battery stacking system includes a quality inspection device adapted to inspect the cathode, the separator, and the anode before they are transferred to a rotating pick-up prism.

[0053] In one embodiment, the battery stacking system includes alignment devices on each of the first, second, and third feed conveyors, which are configured to align the electrodes and the separator when they are on the conveyors.

[0054] In one embodiment, the battery stacking system includes an alignment device on each of the rotary transfer devices, the alignment device being configured to align the electrodes and the separator as they move continuously and are transferred to the rotary pickup prism.

[0055] This disclosure relates to a battery manufacturing apparatus capable of forming battery stacks using a continuous slitting and laminating process by sequentially controlling multiple parameters, including the aforementioned novel features, such as (but not limited to) in various embodiments, the alignment of anode and cathode sheets, the output speed of a feed conveyor, and the pressure applied to the battery materials. The battery manufacturing apparatus includes various sensors, including but not limited to pressure sensors, alignment sensors, tension sensors, temperature sensors, vibration sensors, and cameras, to ensure accurate stacking and quality control. Attached Figure Description

[0056] The foregoing summary of this disclosure and the following detailed description are better understood when read in conjunction with the accompanying drawings. For the purpose of illustrating this disclosure, exemplary constructions of the invention are shown in the drawings. However, the disclosure and invention herein are not limited to the specific methods and facilities disclosed herein.

[0057] Figure 1 A system for transferring electrodes according to one embodiment is shown.

[0058] Figure 2A-2C Different stages of the operation for releasing battery stack material according to one embodiment are shown.

[0059] Figure 3 A battery stacking station according to one embodiment is shown.

[0060] Figure 4-7B A battery stacking system according to one embodiment is shown.

[0061] Figure 8 A slitting apparatus according to one embodiment is shown.

[0062] Figure 9 It shows Figure 8 The second view of the slitting device.

[0063] Figure 10A and 10B The main body of a slitting apparatus according to another embodiment is shown.

[0064] Figure 11A and 12 B illustrates a vacuum conditioning system according to one embodiment.

[0065] Figure 13 A system including a slitting device according to one embodiment is shown.

[0066] Figure 14 The steps of a method according to one embodiment are shown.

[0067] Figure 15 A system including a buffer device according to one embodiment is shown.

[0068] Figure 16 A buffer device according to one embodiment is shown.

[0069] Figure 17 It shows Figure 15 The buffer device includes a thin film material.

[0070] Figure 18 A conveying section of a buffer device according to one embodiment is shown.

[0071] Figure 19 shows a schematic block diagram of method steps according to one embodiment. Detailed Implementation

[0072] A better overall understanding of this disclosure can be achieved by reading the following detailed description in conjunction with the accompanying drawings, descriptions of the drawings, abstract, background information, technical fields, and related headings. The same reference numerals appearing in different drawings denote the same elements or functionally equivalent elements. Elements listed in the abstract are not referenced but refer to elements in the detailed description and related disclosure by way of association.

[0073] In the following detailed description, reference is made to the accompanying drawings, which illustratively illustrate possible industrial embodiments of the disclosure centered on an improved battery stacking system. The detailed description of the embodiments is sufficient to enable those skilled in the art to practice this disclosure. It will be understood that each sub-feature or element described in this embodiment, while unique, is not necessarily exclusive and can be combined in different ways in a number of other possible embodiments as they exhibit novel features. It will be understood that the position and arrangement (e.g., geometric parameters) of the various individual elements in each disclosed embodiment can be modified without departing from the spirit and scope of this disclosure. The disclosed devices can be modified based on known design parameters to implement this disclosure in these particular types of operation. Other variations will also be recognized by those skilled in the art. Therefore, the following detailed description should not be considered limiting.

[0074] In short, this technical solution relates to systems, methods, and apparatus used in the manufacture of battery stacks. The technical solutions described herein can be combined and used in the same system in some embodiments, while in other embodiments they can be independent of each other.

[0075] The anode and cathode are collectively referred to as electrodes. An assembly consisting of alternating anodes and cathodes, and the separators between adjacent anodes and cathodes, is called a battery stack. The anode, cathode, and separator are collectively referred to as battery materials.

[0076] System for transferring electrodes to battery stacks

[0077] As mentioned above, existing methods for stacking electrode and separator materials struggle to ensure precise alignment between multiple layers, leading to uneven pressure distribution, mechanical stress on the electrodes and separators, performance degradation, internal short circuits, and thermal runaway. Due to manufacturing constraints associated with using continuous separator webs, existing methods also struggle to check the placement accuracy of the electrodes and battery stack. If the layers are not accurately aligned, the battery stack must be trimmed, or the total battery capacity will be reduced, resulting in higher manufacturing costs and material waste. The stacking system 100 addresses these problems by allowing the continuous stacking of diced electrode and separator materials, while maintaining a level of precision and manufacturing speed unattainable by existing methods.

[0078] Looking at it now Figure 1 The diagram shows a system 100 for transferring electrodes to a battery stack.

[0079] The system includes a first conveying device 100 for conveying a first electrode 115 toward a picking device 170. The system also includes a second conveying device 120 for conveying a second electrode 125 toward the picking device 170. The picking device 170 is adapted to pick up the electrode from a gripping device 150 and then place the electrode at a battery stack 180 positioned at a battery stacking station 185.

[0080] One of electrodes 115 and 125 is typically an anode, and the other is a cathode. The conveying devices 110 and 120 can be any type of conveying device suitable for this system, such as a conveyor.

[0081] The feed conveyor system for battery stacking, namely the first conveyor 110 and the second conveyor 120, is designed to deliver slit anode, cathode, and separator sheets from upstream processes with high precision and synchronization to the transfer unit 150 and the rotary pick-up unit 170. Examples of slitting devices are disclosed below. Each feed conveyor may be equipped with a slitting device for each of the anode, cathode, and separator. These conveyors contain one or more channels or belts dedicated to different materials (anode, cathode, separator) to ensure seamless feeding into the stacking process. These conveyors are equipped with features such as vacuum-assisted gripping mechanisms, sensors, and alignment devices to ensure that each component is properly positioned and aligned before entering the stacking system 100. Advanced systems typically integrate tension control devices, speed regulation devices, and robotic arms to manipulate easily deformable, delicate, and thin materials, particularly separators. Additionally, real-time quality inspection devices, such as optical or X-ray inspection systems, can be incorporated along the conveyors to detect defects in the material before it reaches the stacker, thereby ensuring quality consistency and minimizing the risk of downstream problems.

[0082] The two conveying devices 120 are typically of the same type, but this type may vary depending on the implementation. In embodiments where the conveying device is a transmitter, the conveying device may, in some embodiments, be a transmitter adapted to use suction to convey the electrodes to keep them attached to the surface of the conveying device. In some embodiments, the transmitter may be inverted and convey the electrodes 115 on the bottom side rather than the top side. In embodiments employing an inverted transmitter, some type of mechanism is required for attaching the electrodes to the transmitter, which may be suction.

[0083] The system also includes: a first nest 130 adapted to receive a first electrode 115; and a second nest 135 adapted to receive a second electrode 125. Figure 1 In the middle, there is an electrode 127 positioned in the second nest 135.

[0084] These nests are adapted to receive electrodes from the conveyor. In some embodiments, an intermediate device may be provided to facilitate transfer from the conveyor devices 110, 120 to the corresponding nests 130, 135. In some embodiments, a Bernoulli gripper is positioned between the conveyor devices 110, 120 and the corresponding nests, which uses suction to prevent the electrodes from falling prematurely into the nests.

[0085] Nests 130 and 135 are adapted to transfer electrodes 115 and 125 to gripping device 150. The gripping device includes a first gripper 155 and a second gripper 160, the first gripper and the second gripper being adapted to pick up electrodes from nests 130 and 135 and deliver the electrodes to pickup device 170.

[0086] The gripping device 150 is adapted to move back and forth between nests 130 and 135 to alternately pick up the anode and cathode and deliver them to the picking device 170.

[0087] The grippers 155 and 160 may employ suction to pick up electrodes 115 and 125 from the nest. The grippers 155 and 160 may include vacuum chucks. The grippers 155 and 160 may be further adapted to use an airflow to push the electrodes away from the grippers 155 and 160 when releasing the electrodes to the pickup device 170.

[0088] The nest may include an air bearing on its bottom surface, the air bearing being adapted to receive electrodes from a transmitter and / or any optional intermediate device. In some embodiments, the nest may be adapted to employ suction and / or air at different locations within the nest, such that some portions or areas of the nest provide air as a buffer for the electrodes, while other portions or areas of the nest utilize a vacuum to attach the electrodes to the nest. This can be achieved using a vacuum-preloaded air bearing with switchable vacuum areas. In one embodiment, switching between generating a vacuum or air or jet is achieved using a built-in baffle within the nest.

[0089] The nest can be adapted to move back and forth (i.e., up and down) along a vertical axis. When the nest is in the bottom position, the electrode 127 is received at the nest, and when transferred to the gripper 160, the bottom of the nest moves upward to be in the top position. In some embodiments, the nest moves up and down by means of an axis positioned on an eccentric leaflet that rotates eccentrically about an axis and causes the nest to move up and down during one rotation.

[0090] In some embodiments, nests 130, 135 include alignment mechanisms for aligning electrodes. Advantageously, the electrodes are positioned in the same or substantially the same location each time they are transferred to the gripping device 150. In some embodiments, the alignment mechanism includes one or more brushes that are pushed against one or more sides of the electrode. In one embodiment, the alignment device includes one or more wheels for pushing or pulling one or more sides of the battery material to maintain a predetermined alignment. In one embodiment, the alignment device includes one or more vacuum or jet regions for pushing or pulling one or more sides of the battery material to maintain a predetermined alignment.

[0091] After electrodes 115, 125 have been transferred from their respective nests 130, 135 to the grippers 155, 160 of the gripping device 150, the gripping device moves toward the pickup device 170. When the grippers 155, 160 holding the electrodes reach the pickup device, the electrodes are transferred to the pickup device 170. In some embodiments, the electrodes are gripped by the pickup device via suction. In some embodiments, the suction of the gripping device 150 is turned off when the pickup device 170 contacts the respective grippers 155, 160. In some embodiments, the suction employed by the pickup device 170 is stronger than that of the grippers 155, 160, which allows it to pick up electrodes 115, 125 from the grippers without releasing the suction of the grippers 155, 160.

[0092] In some embodiments, the electrode can be transferred to another.

[0093] In some embodiments, the gripping devices 150 may be positioned such that one gripping device 160 grips the electrode 127 in the nest, while the other gripping device is positioned to release another electrode to the pickup device 170. In such embodiments, the gripping devices 150 stop or move very slowly at both the gripping and releasing positions. As will be understood, in such embodiments, the gripping devices 150 have two mirror-image positions: one where the gripping device picks up the anode and simultaneously releases the cathode, and another where the gripping device picks up the cathode and simultaneously releases the anode.

[0094] In some embodiments, the electrodes may be transferred to another subsequent station of the battery stacking system, rather than to the pick-up device 170. In some embodiments, the electrodes may be transferred directly from the gripping device 150 to the battery stacking station 185.

[0095] In some embodiments, the picking device includes multiple surfaces and is adapted to rotate (optionally eccentrically rotate) to first pick up the electrode from the gripping device 150 and then place the electrode at the battery stacking station 185.

[0096] In some embodiments, the pickup device 170 is also adapted to pick up and release separator material positioned between the anode and cathode on the battery stack. The separator material may be delivered together with the electrodes or may be delivered separately. In some embodiments, the pickup device 170 first picks up a layer of separator material, then picks up the electrodes on top of the separator material, and then simultaneously transfers both the separator material and the electrodes onto the battery stack 180.

[0097] When independently transporting separator material, the rotary pickup device can be configured to pick up sheets of slit separator material from the alternating surfaces or boots of electrodes 115 and 125 from the face of the upstream slitting region using vacuum and air jets to hold and position the slit sheets. In some embodiments, the rotary pickup device 170 picks up multiple layers simultaneously, such as electrodes and separators. If the rotary pickup device 170 is configured to pick up multiple layers, there are two different pickup strategies. The first is "conventional" pickup, in which the rotary pickup device 170 is configured to first pick up one layer of separator. Then, the electrodes are placed on top of the separator material, and both the separator material and the electrodes are then transferred simultaneously onto the battery stack 180. This strategy relies on the porosity of the separator. If the porosity is too low, the electrodes cannot be picked up at high speed.

[0098] The second pickup strategy is "reverse" pickup, which uses a high-flow-rate "leakage" end effector to pick up the electrodes first, followed by the separator. The high-flow-rate end effector allows the separator to be picked up and held securely by a constant airflow (generating suction) around the electrode edges. The reverse pickup method is independent of porosity, thus allowing the pickup of non-porous separators. This allows the stacked system 100 to manipulate a wider range of battery topologies, including prismatic, pouch, solid-state, or lithium foil-based battery topologies.

[0099] In some embodiments, the system further includes a rejection mechanism for rejecting faulty or misaligned electrodes. The system may also include an inspection component, such as an optical camera, for determining whether an electrode is faulty or misaligned. Such a rejection mechanism is preferably positioned between the transport devices 110, 120 and the corresponding nests 130, 120. In some embodiments, the rejection mechanism takes the form of a rejection chute into which the electrode falls. In cases where the transport devices 110, 120 are inverted conveyors that attach electrodes using suction, rejecting the electrode may include releasing the suction, and an air jet may be used to push the electrode toward a rejection chute positioned directly below the respective transport device 110, 120.

[0100] Battery quality is a measure of the accuracy of electrode placement. Quality inspection systems for battery stacking ensure that electrodes (anodes and cathodes) and separators are correctly aligned and defect-free before and during the stacking process. These systems typically employ advanced technologies such as optical, X-ray, or laser-based sensors to detect misalignments, foreign particles, or material defects that can affect battery performance and safety. Real-time monitoring is essential because even minute deviations can lead to short circuits, capacity degradation, or thermal events. Inspection systems may also include impedance spectroscopy analysis and other electrical testing methods to verify the integrity of the stacked layers. These quality control systems are integrated with automation, enabling continuous monitoring and corrective action to minimize defects and ensure high reliability of the final battery stack for electric vehicles, energy storage, and other applications. In one embodiment, the quality inspection device includes an optical camera (not shown) for determining whether electrodes are faulty or misaligned. A control box (not shown) may be configured to receive real-time images of the edges of the battery material to detect misalignments and defects. If a misalignment or defect is detected, the control box sends a signal to a rejection device, battery stacking station 185, or battery stack removal system to initiate rejection of individual battery material sheets or the entire battery stack.

[0101] In some embodiments, the quality inspection system is configured to generate a digital twin model of the entire battery stack throughout the stacking process. Using a digital twin model in the quality inspection of a battery stacking system offers numerous benefits by creating a real-time virtual copy of the physical manufacturing process. This advanced approach allows manufacturers to simulate, monitor, and optimize production without disrupting workflows. The digital twin model can track and analyze data from individual sensors within the battery stacking system, providing a profile of potential defects, misalignments, or inconsistencies in the electrode and separator stacks. Manufacturers can minimize downtime and reduce waste by anticipating problems before they occur and making immediate adjustments. Furthermore, the digital twin model enhances predictive maintenance by monitoring machine health and performance, preventing failures. Overall, this approach improves the accuracy, efficiency, and reliability of battery manufacturing processes, ensuring higher quality control standards and reducing production costs.

[0102] In some embodiments, the system further includes an electrode cleaning station located upstream of the respective conveying devices 110, 120. The cleaning station is adapted to clean the electrodes and optionally remove electrode burrs before conveying them to the pickup device.

[0103] Such an electrode cleaning station may include two air bearings positioned opposite and close to each other, through which the electrode is transported for cleaning and deburring using air pressure. The distance between the two such air bearings is preferably approximately the same as or slightly larger than the electrode, and may be less than 2 micrometers.

[0104] In some embodiments, the cleaning station may include other electrode cleaning methods, such as ultrasonic cleaning, solvent bath, or electrolytic cleaning. The cleaning station may also include other electrode deburring methods, such as mechanical brushing, sandblasting, or chemical deburring.

[0105] Technical solutions for retaining and releasing battery materials

[0106] This disclosure also relates to methods and systems for holding and releasing battery materials, which can be both electrode and separator materials. Such methods and systems can be implemented, for example, in the electrode transfer system described above. Figure 2 is a main diagram of this technical solution, but reference is also made thereto. Figure 1 The system.

[0107] When transferring electrodes from, for example, pick-up device 170 to battery stacking station 185, a process of gradually releasing the electrodes in several steps can be employed, rather than releasing them all at once. Releasing only portions of the electrode at a time allows for a smoother and more accurate transfer, also reducing the risk of electrode damage. In the embodiments described below, the gradual transfer of the electrodes is performed by a pick-up device that includes a vacuum component for attaching the electrodes to the surface of the pick-up device.

[0108] To achieve progressive transfer, the surface of the pickup device includes multiple regions in which a vacuum can be applied independently. Each vacuum region includes means for maintaining the position of tracking that particular region.

[0109] To maintain tracking of each independent region, independent devices can be used. Such devices can be independent processing devices that include processing circuitry, such as microcontrollers or digital signal processors, which may include one or more programmable processors, application-specific integrated circuits, field-programmable gate arrays, or combinations thereof.

[0110] For example, one example of such a device is an output comparison device adapted to compare one value with another and optionally perform an action when a specific value is detected or exceeded.

[0111] Furthermore, the independent processing unit can record a predetermined position where the vacuum of the pickup device is suitable for being turned off. When this predetermined position is reached for a specific area, the independent unit for that area sends a signal to turn off the vacuum. This also applies to the independent unit for the next area, and then the next area after that, and so on.

[0112] In some embodiments, the independent device is adapted to transmit its position to another processing or computing device. This computing device may be associated with the pickup device 170, which maintains a tracking position of the pickup device. The computing device of the pickup device 170 may be adapted to turn the vacuum region on and off. Data between the processing device and / or the computing device is preferably transmitted wirelessly.

[0113] This is shown in Figure 2A-2C In. Figure 2A In this process, the pickup device uses a vacuum to attach electrode 205 to its surface. The surface of the pickup device holding electrode 205 includes a first vacuum region 230, a second vacuum region 240, and a third vacuum region 250. This also applies to... Figure 2B and Figure 2C However, the reference numerals for the accompanying drawings were omitted.

[0114] When the pickup device is from Figure 2A The position in the middle is oriented towards Figure 2C As the release position rotates, it passes through a predetermined level 210 when the vacuum is turned off. Since each region 230, 240, and 250 is associated with its own processing device, the corresponding processing device keeps track of its own position relative to the predetermined position 210 and turns off the vacuum when it reaches that position.

[0115] This means that in Figure 2B In the middle, the first vacuum zone 230 has been turned off, and the second vacuum zone 240 is about to be turned off. When the pickup device 170 arrives... Figure 2C When the third region 250 is in position, the electrode 205 is also released, causing it to be released from the pickup device toward the battery stack station 185. In some embodiments, it can be released at almost no distance from the battery stack, while in other embodiments, it can be released and fall a certain distance before reaching the battery stack.

[0116] In some embodiments, the pickup device 170 may also be adapted to use air to push the electrode 205 away from the pickup device when it is released. This could mean that when the respective regions 230, 240, and 250 pass through the predetermined position 210, the vacuum is turned off and the air jet is turned on.

[0117] Battery stacking station and battery removal device and method

[0118] Figure 3 A battery stacking station 300 according to one embodiment is shown. The battery stacking station 300 may be... Figure 1 or Figure 2C Battery stacking station 185.

[0119] The battery stacking station 300 includes a platform 310 on which the battery stack is positioned. The battery stack typically includes alternating anode and cathode layers with a separator material between them. The separator material can be in the form of a continuous sheet folded between the electrodes, or it can be in the form of a single sheet.

[0120] The battery stacking station 300 also includes four walls surrounding the platform and a hollow interior.

[0121] In some embodiments, platform 310 is adapted to be lowered as a battery material layer is placed thereon. The battery material layer can be positioned on platform 310 by pick-up device 170. In some embodiments, station 300 may include a lifting mechanism that can lower and raise platform 310. In some embodiments, the lifting mechanism may include a screw, such as a set screw, positioned inside station 300 below platform 310.

[0122] The battery stacking station 300 also includes a vacuum port 320 for connecting to a vacuum source. When the vacuum source is connected to the vacuum port 320, a vacuum is created inside the battery stacking station, which attaches battery material to the platform 310.

[0123] By using a vacuum to suction and attach battery materials to platform 310, a more robust system less prone to misalignment and other positional errors can be achieved without mechanical means that could easily damage the battery stack. It also helps stabilize the battery stack and simplifies the process of positioning new battery materials on it.

[0124] In some embodiments, station 300 may further include a flexible clamping member 330 designed to contact the top layer of the battery stack to further secure the battery stack to platform 310. The flexible clamping member may include two flaps positioned on a rotator, wherein the two flaps extend in opposite directions. When a next layer of battery material is placed on the battery stack, the rotator is adapted to rotate 180 degrees such that, during the placement of the top layer, the flap pressing against the battery stack is removed, while the other flap rotates onto the top of the newly placed layer.

[0125] Figure 4 -7 illustrates a system 400 for removing battery stacks, the system comprising... Figure 3 The illustrated embodiments show two battery stacking stations 405 of different embodiments, and the method steps for removing a battery stack using two such battery stacking stations 405 are shown. Although not all features are labeled on the two battery stacking stations 405, they typically include the same features. In some embodiments, the battery stacking stations 405 are identical.

[0126] Each battery stacking station 405 includes a base plate 410 on which the battery stack is placed. It also includes a lowerable front wall 420. The stacking station 405 may also include a hollow interior and include or be connected to a vacuum source that generates suction to attach the battery stack to the base plate 410. In some embodiments, the base plate 410 is fixed and cannot be lowered or raised, as are the other three walls besides the front wall 420.

[0127] The system also includes a stack removal device 450, which includes forks 455 adapted to extend from the device 450 and are adapted to be positioned below the formed battery stack.

[0128] In some embodiments, the battery stacking station 405 may include a recess or channel 435 in the base plate, the recess or channel being adapted to receive a fork 455 positioned below the base plate 410 and thus enabling the fork 455 to be positioned below the base plate 410, i.e., at the location of the bottom layer of the battery stack.

[0129] Station 405 may be positioned on an arm or other mechanical conveying device 430 adapted to convey battery stack station 405 along at least two axes. In some embodiments, station 405 may be freely movable in space by the conveying device 430.

[0130] Figure 5 The diagram illustrates how the battery station 405 can move vertically and laterally in two opposite directions to position itself within the system. The battery station has at least four positions: upper right, lower right, upper left, and lower left. In some embodiments, the battery station 405 can be freely and continuously positioned between any of these positions.

[0131] In some embodiments, the upper right position is the position where the battery stack is positioned on the battery station 405, and the lower right position is the position where the removal device 450 removes the completed battery stack from the station 405.

[0132] Figure 6A , 6B Figures 7A and 7B illustrate how to remove a battery stack from a battery stacking station 405 using the stack removal device 450.

[0133] First, move the removal device 450 toward the bottom station 405 and position it above it, as follows. Figure 6A As shown. Then, the stack removal device 450 is moved relative to the bottom station 405 such that it presses down on the top (not shown) of the battery stack positioned on the battery stacking station 405, as shown. Figure 6B As shown. In some embodiments, this means lowering the stack removal device 450, while in other embodiments, it means raising the station 405.

[0134] Then, lower the front wall of the battery stack station 405 to the bottom position, as follows: Figure 7A As shown. In some embodiments, the removal device 450 may include a front barrier 460, which is adapted to be positioned such that the vacuum pressure within the station 405 is maintained even when the wall 420 is lowered.

[0135] Subsequently, the fork 455 of the removal device 450 extends forward and is positioned in the recess 435 of the battery stacking station 405. Once the fork 455 is positioned, the front part 465 of the removal device can press down on the battery stack to keep it firmly in place.

[0136] Then, the battery removal device 450 can retract from the battery stacking station 405 and move the battery stack to another location for storage or further transport.

[0137] According to one aspect, a system for battery stacking and removal is provided. The system includes two battery stacking stations 405, each including a base plate, three fixed walls, and a movable wall 420. The system also includes a battery removal device 450, which includes components for gripping and moving the battery stack from the battery stations.

[0138] Throughout this document, various devices utilize suction to attach electrode and / or diaphragm materials to the device. This suction can be achieved using a pressure differential, which can be achieved using a vacuum.

[0139] In some embodiments, suction can be replaced by other means of attaching material to a surface. Such means may be, for example, mechanical clamping components, electrostatic components, adhesive or sticky surfaces, and similar solutions.

[0140] Slitting device

[0141] In summary, this technical solution relates to an apparatus for cutting thin film material into parts, referred to herein as a slitting apparatus. The apparatus includes a body having at least two faces, the body being adapted to rotate about an axis, wherein each face is adapted to receive and attach the thin film material to that face. The slitting apparatus also includes a cutting device adapted to cut the thin film material while it is attached to one of these faces. The body is adapted to rotate in a motion including initial acceleration followed by deceleration, the motion including a complete stop, and the cutting device is adapted to cut the thin film material after deceleration. During rotation, the slitting apparatus is adapted to extract a quantity of thin film material, wherein a single extraction and / or rotational operation typically extracts an amount of thin film material corresponding to the size of one of the faces of the apparatus. After the thin film material has been cut, it can be transferred to another device for conveying the thin film material to a battery stack. The acceleration and deceleration of the indexing motion are typically rapid to achieve high speeds for the slitting apparatus and the systems operating therein.

[0142] This disclosure is based on the understanding that cutting separator material into pieces at very high speeds can be highly advantageous when manufacturing prismatic battery stacks. Because separators are difficult to manipulate, current alternative methods involve laminating or otherwise treating them to make them easier to handle. However, cutting them into pieces at the same speed as stacking the cells can improve the battery manufacturing process and avoid the need for lamination or similar treatments.

[0143] To achieve very high manufacturing speeds, such as 0.2 seconds per battery layer, the separator also needs to be slit and cut at the same speed, i.e., at most 0.2 seconds per slice. Therefore, this technical solution aims to provide an apparatus that can not only slit and cut the separator material, but also slit and cut it at a very high speed.

[0144] For the purposes of this disclosure, a film material refers to a thin and at least somewhat flexible material, which may be, for example, nonwoven fibers, polymer films, and naturally occurring substances (such as rubber and asbestos). Film materials may be in the form of sheets, webs, or pads, and may include oriented or randomly oriented fibers. Film materials may comprise single-layer or multi-layer materials.

[0145] For the purposes of this disclosure, indexing motion is a motion intended to position an object at a specific location, typically with high precision. The most common indexing motion mentioned in this disclosure is repetitive motion, which includes acceleration (which may be rapid acceleration) followed by deceleration (which may be rapid deceleration). Indexing motion may also include a complete stop after deceleration. In some embodiments, one iteration of indexing motion includes a 90-degree rotation. In some embodiments, indexing motion refers to motion that comes to a complete stop at regular intervals.

[0146] Looking at it now Figure 8 An embodiment of the slitting device 800 is shown.

[0147] The slitting device includes a body 810 comprising four substantially flat surfaces 820, 830, 840, and 850. In some embodiments, the body 810 may include more or fewer surfaces, as long as there are at least two surfaces. Typically, the surfaces of the body 810 are flat or substantially flat. In some embodiments, the corners of these surfaces are rounded to prevent the film material from cracking.

[0148] In some embodiments, device 800 may include six faces. In some embodiments, all of these faces have the same shape and size, while in some embodiments, the size and / or shape of these faces may be different.

[0149] Although surfaces 820, 830, 840, and 850 can be identical and their positions change with the rotation of the main body 810 of the cutting device, in order to Figure 8 For this purpose, they will be referred to as first face 820, second face 830, third face 840, and fourth face 850. The reference numerals 820, 830, 840, and 850 may also be interchangeably referred to as first position 820, second position 830, third position 840, and fourth position 850.

[0150] At least one of the positions of the face of the slitting device is a cutting position, in which the film material is adapted to be cut. At least one of these positions is a receiving position, adapted to receive film material from a film transfer device or from a buffer device. In some embodiments, at least one position is an output position, adapted to transfer the film material to a picking device after it has been cut. In some embodiments, these positions may overlap, particularly in embodiments where the slitting device includes fewer faces (e.g., two faces). For example, a first position may be both a receiving position and a cutting position, and / or a second position may be both a cutting position and an output position.

[0151] Surfaces 820, 830, 840, and 850 are adapted to receive thin film material fed from the transfer device. These surfaces are also adapted to attach thin film material to these surfaces.

[0152] In some embodiments, each facet 820, 830, 840, 850 is adapted to have a film material attached thereto by suction. Suction may be provided by a vacuum source connected to the slitting apparatus. In some embodiments, these faces may be adapted to have the film material attached by other means, such as electrostatic, mechanical, or by using an adhesive or sticky surface.

[0153] In some embodiments, the slitting device is adapted to allow independent control of each face for attaching the film to the respective face. In some embodiments where attachment is achieved by suction, the suction size can be adjusted independently for each face. In some embodiments, the slitting device 800 is adapted to simultaneously turn the attachment of the film material on or off for all faces. In embodiments where attachment is achieved by suction, this may mean providing the same amount of suction for all faces.

[0154] The body 810 is adapted to rotate about a central axis. The slitting device is typically adapted such that the body 810 rotates symmetrically about this axis, but in some embodiments, the body 810 may also rotate asymmetrically.

[0155] In some embodiments, the body 810 rotates in an indexing motion such that it first accelerates relatively quickly from a standstill, then decelerates relatively quickly, in order to position the film material for cutting and / or being picked up by a pick-up device. After deceleration, it typically comes to a complete stop, but in some embodiments, it may include a lower rotational speed without coming to a complete stop. Figure 8 In one embodiment, a rotational operation including one indexing movement will rotate the main body by 90 degrees, causing the position of the first surface 820 to change to the second position 830, the position of the second surface 830 to change to the third position 840, and so on.

[0156] The slitting device 810 also includes a cutting device 860. In some embodiments, the cutting device 860 may be incorporated into the same structure as the body 810 of the slitting device, while in some embodiments, such as Figure 8 In the embodiment shown, the cutting device is located outside the body 810 and is not connected to the body.

[0157] The cutting device 860 includes a cutting blade 165 adapted to cut the film material when it is attached to the surface of the slitting device 800. In some embodiments, the cutting blade 865 may be a physical cutting blade, such as a knife or a sharp edge. In some embodiments, the cutting blade 865 may be a laser or another type of energy source. In some embodiments, the cutting blade 865 may include a heated blade or a heated wire.

[0158] In some embodiments, each facet 820, 830, 840, 850 may include an internal cutting device that cuts the film material from the inside relative to the body 810. Having an internal cutting device on each facet makes it easier to cut the film material during the movement of the slitting device, which may be advantageous in some embodiments.

[0159] In some embodiments, each face 820, 830, 840, and 850 of the slitting device 800 includes a feature 870 adapted to receive a cutting blade 865 of the cutting device 860. Figure 8 In the illustrated embodiment, feature 870 is a notch adapted to receive the physical cutting blade 865.

[0160] exist Figure 8 In the illustrated embodiment, the thin film material has four distinct locations 820, 830, 840, and 850, each corresponding to one location. Now, based on... Figure 8 The illustrated embodiment details the process of rotating the main body 810 of the slitting device and the related aspects.

[0161] The first position 820 is the first surface, and when the slitting device 800 rotates, the film material is transferred to the first surface. As the first film material is pulled onto the first surface 820, it adheres to the first surface 820 via the slitting device (e.g., by suction). Then, the body 810 rotates, causing the film material positioned on the first surface 820 to become positioned on the second surface 830, and new film material is extracted from the transfer device onto the first surface 820. When the film material is positioned on the second surface 830, it is cut by the cutting blade 865 of the cutting device 860.

[0162] Then, the body 810 rotates again, transferring the film material from the second surface 830 to the third surface 840. Since the film material was cut at the second surface 830, it is no longer part of a material web or continuous sheet, but can be transferred. In some embodiments, the film material is transferred to another device adapted to pick up the film material from the third surface 840.

[0163] Next, the main body 810 rotates again. If the film material was transferred at the third surface 840, then there is no film material at the fourth surface 850. However, in some embodiments, the slitting device 800 may be adapted to transfer the film material from the fourth position.

[0164] In some embodiments, transferring the film material from either the third or fourth surface includes releasing the film material from its adhesion to that surface. In cases where the film material is being drawn in by suction, this would include releasing or reducing the suction.

[0165] In some embodiments where the film material is transferred at the third surface 840 or the fourth position 850, the suction can be simply released, and the film material falls onto the transfer device.

[0166] In some embodiments, the slitting apparatus 800 may further include a mechanism for rejecting defective or damaged film material pieces that have already been cut. This mechanism may include using air to push the cut film material away from the surface. Typically, this rejection is performed at a second position 830 or a third position 840, or between the second and third positions. The air used to push the film material away may also be generated using the same source that applies suction to the surface of the body 810; for example, the suction may be reversed to positive pressure to blow away the sheet.

[0167] In some embodiments, the slitting device 800 further includes a base 880 on which the body 810 is positioned. In some embodiments including the base 880, the slitting device 800 may be adapted such that the body 810 can pivot and / or deflect relative to the base 880. This can be achieved by a deflection mechanism. By providing such a mechanism, it is convenient to transfer the already cut film material to the picking device when the picking device physically contacts the slitting device 800 while picking up the film material.

[0168] In some embodiments, the base 880 may include a motor 885 adapted to rotate the slitting device and optionally perform other operations. In some embodiments, the motor may be located elsewhere, for example, inside the body 810.

[0169] In some embodiments, each face 820, 830, 840, and 850 of the body 810 can be independently deflected to allow the pickup device to pick up the film material without the risk of collision or interference with the slitting device. In some embodiments, this deflection can be achieved by a spring member associated with each face. In some embodiments, the deflection can be achieved by foam or other elastic materials. The foam can be disposed on the face such that it contacts the diaphragm material, or it can be disposed behind a surface portion of the face.

[0170] Looking at it now Figure 9 , showed Figure 8 Different views of the slitting device 800. Figure 9 The diagram also shows film material 905 being fed onto the slitting device 800. Film material 905 can be fed from any source capable of outputting film material to the slitting device 800 without causing the film to break or be damaged. Because the indexing motion employed in embodiments of the slitting device involves rapid acceleration, it may be necessary to extract the film material from a source with low or no inertia and / or low or no friction. In some embodiments, the film material is extracted from a buffer device adapted to specifically output the film material to the slitting device.

[0171] As previously described, the slitting device 800 can use suction to attach film material to the surfaces 820, 830, 840 and 850 of the body 810. Figure 9 A tube 910 is shown that can be connected to a vacuum source, which can be used to adjust the suction of the surface.

[0172] In some embodiments, the slitting device 800 may further include an alignment rod 920, which ensures that the film material 905 is fed onto the body 810 of the slitting device 800 in an optimal manner.

[0173] Looking at it now Figure 10A An alternative embodiment of the main body 1000 of the slitting device 800 is shown.

[0174] In this embodiment, the body 1000 includes six surfaces 1010. Similar to the embodiment with four surfaces, the film material can be attached to a single surface independently or to all surfaces together, depending on the implementation.

[0175] In some embodiments, each face of the body 1000 can be deflected inward by using one or more springs.

[0176] In some embodiments, each face of the body 1000 includes a feature 1010, which, in the case where the cutting edge 865 includes a laser, is adapted to receive a laser beam or the like. This feature 1010 can easily deflect the laser beam, preventing it from damaging the body 1000.

[0177] In some embodiments, including Figure 8 In both embodiments shown in Figure 10, the surface material of the main body of the slitting device, i.e., the surface on which the film material is positioned and attached, is made of any type of plastic material, aluminum, or titanium. In some embodiments, the material may be glass-impregnated nylon.

[0178] Figure 10B Another view of a slitting device 1000 with six sides is shown, which shows a face 1010 and recesses 1015 between the faces, through which the cutting blade of the slitting device can be passed to cut thin film material. Figure 10B A vacuum supply unit 1040 for providing suction to surface 1010 is also shown.

[0179] Looking at it now Figure 11A and Figure 11B A mechanism for adjusting the suction of the surface of a body for attaching thin film material will now be described. Figure 11A The closed position is shown, preventing air from entering. Figure 11B The open position for allowing air to enter is shown.

[0180] This mechanism can be used regardless of the number of faces of the body, and can be used on all faces simultaneously, or on each face independently. The mechanism is preferably located on the inside of the body 810 of the slitting device. As will be understood, the body 810 may include one or more vacuum adjustment mechanisms 1100.

[0181] Mechanism 1100 includes valve 11710, which can be opened and closed to regulate the amount of air or other gas entering, which in turn regulates the vacuum level. Valve 11710 is infinitely positionable between an open position and a closed position, allowing stepless adjustment of the amount of air entering, rather than having only two discrete positions.

[0182] The mechanism also includes a plurality of holes 1120 adapted to allow air or gas to pass through in order to apply suction to the face of the slitting device. The holes 1120 are substantially positioned on the surface of the face of the slitting device.

[0183] The mechanism may also include a spring 1130, which can automatically or semi-automatically adjust the amount of air entering the mechanism to regulate the vacuum. When the vacuum inside the mechanism increases, the spring 1130 contracts, which reduces the spring's elongation and opens the valve 1110, allowing more air to enter the mechanism. When more air enters, the vacuum decreases, which reduces the pressure on the spring and causes the spring to elongate, which closes the valve 1110 and increases the vacuum inside the mechanism.

[0184] By incorporating an automatically adjustable mechanism for regulating vacuum, a more robust and efficient suction application can be achieved on the surface of the slitting device.

[0185] Looking at it now Figure 12 An exemplary system 1200 is shown, in which a slitting device 800 according to the present disclosure can be used.

[0186] The slitting device 800 requires a certain type of device to feed the film material. Because the indexing motion used by the slitting device to extract the film material involves rapid acceleration followed by rapid deceleration, and typically includes complete stopping, the film material must be fed in a virtually frictionless manner. This, in turn, means that the extraction of the film material is almost unaffected by inertia. If this is not the case, using this indexing motion to extract the film material will damage the film, or it may not be possible to extract it at all.

[0187] In some embodiments, the slitting device 800 may be fed by a buffer device 1210, which in turn receives the film from the film dispensing device 420. The film dispensing device 1220 may be an unwinder assembly comprising a roll of film material wound around an air chuck.

[0188] It is not possible to extract film material from such a film dispensing device using the indexing motion described herein. Therefore, an intermediate device in the form of a buffer device 1210 may be required.

[0189] The buffer device 1210 is adapted to receive film material from the film dispensing device 1220 at a constant speed and output the film material to the slitting device at a variable speed, wherein the variable speed can be the indexing motion of the slitting device extracting the film material from the buffer device 1210.

[0190] In some embodiments, the buffer device 1210 may include a first conveying section, a buffering section, and a second conveying section, wherein the film material is adapted to travel through the first conveying section at a constant speed and through the second conveying section at a variable speed. In some embodiments, both the first and second conveying sections include air bearings, such that the film material travels in the air to achieve substantially frictionless and / or substantially inertial transfer of the film material.

[0191] In some embodiments, the system may further include a pickup device (not shown). This pickup device is adapted to pick up sheets of pre-cut film material from the slitting device 800. In some embodiments, the pickup device includes an arcuate surface that contacts a surface of the slitting device when picking up the cut film material.

[0192] In some embodiments, the pickup device is adapted to pick up thin film material using suction, and therefore may include a suction component for attaching the thin film material to the pickup device. In some embodiments, the pickup device is adapted to also attach electrodes thereto using its suction, while also attaching the cut thin film material. In some embodiments, the pickup device is adapted to transport the thin film material and optionally the electrodes from the slitting device to the battery stack, wherein the thin film material is a separator material used in battery manufacturing.

[0193] Looking at it now Figure 13 A method 1300 for cutting a thin film material into parts according to an embodiment will now be described.

[0194] The method includes transferring 1302 film material onto the surface of a slitting apparatus as described in the embodiments herein, the slitting apparatus comprising a body having at least two substantially flat surfaces for receiving film material, wherein each surface is adapted to attach film material to the surface, and wherein the body is adapted to rotate about an axis.

[0195] The method also includes rotating the main body of the slitting device by an indexing motion 1304, the indexing motion comprising rapid acceleration followed by rapid deceleration. By rotating 1304, the film material is transferred from a first position to a second position on the slitting device. By rotating again, the film material can be transferred again from the second position to a third position, from the third position to a fourth position, and so on, depending on the number of faces included in the slitting device. At least one of these positions is a cutting position where the film material can be cut by the slitting device.

[0196] The method also includes cutting the 1306 film material while the film material is attached to the surface of the slitting device.

[0197] In some embodiments, the method may further include transferring the film material 1308 to the pickup device. In some embodiments, transferring 1308 includes stopping the adhesion of the film material to the surface when the film material is picked up by the pickup device.

[0198] Buffer device

[0199] In summary, this technical solution relates to an apparatus and corresponding system and method for receiving thin-film materials, particularly separator materials used in battery stacks, at a constant speed, and for outputting thin-film materials at a variable speed. Although this apparatus is particularly suitable for battery manufacturing, it can also be used for any type of thin-film material.

[0200] During battery stack assembly, the separator material is fed from the membrane dispensing device at a generally constant or substantially constant speed. However, to cut the separator material into discrete sheets, a certain length of separator material needs to be extracted using indexing motions involving rapid acceleration followed by rapid deceleration (which may include complete stopping) to achieve high-precision material cutting. The inertia of attempting to rapidly extract the separator from the dispensing roll is usually too great to allow for direct extraction from the dispensing device in this manner.

[0201] Therefore, this disclosure provides a buffer device positioned between a film dispensing device that dispenses film material at a constant speed and a film extraction device adapted to extract film material at a variable speed, particularly in indexing movements including acceleration followed by deceleration, which may include a complete stop after deceleration. This buffer device provides a method for extracting film material from a source using inertia and for outputting film material with little or no inertia, enabling extraction of film material at very high speeds and / or very high accelerations. Preferably, acceleration and deceleration occur rapidly, allowing the buffer device and the system in which it operates to operate at high speeds.

[0202] The device includes: a first conveying section in which film material is adapted to travel at a constant or substantially constant speed; a buffering section adapted to contain the film material; and a second conveying section in which the film material is adapted to travel at a variable speed, wherein the variable speed has a minimum speed below the constant speed and a maximum speed above the maximum speed, but wherein the average speed of the variable speed over time is the same as or substantially the same as the constant speed. The adaptation of the film material to travel at a certain speed is also referred to as a buffering device adapted to convey the film material at that speed, although the buffering device may not perform any active conveying steps.

[0203] For the purposes of this disclosure, indexing motion refers to a motion intended to position an object in a specific location with high precision. The most common indexing motion mentioned in this disclosure is an indexing motion that includes rapid acceleration followed by rapid deceleration, which may include complete stopping.

[0204] For the purposes of this disclosure, a film material refers to a thin and at least somewhat flexible material, which can be, for example, nonwoven fibers, polymer films, and naturally occurring substances (such as rubber and asbestos). Film materials can be in the form of sheets, webs, or pads and can include oriented or randomly oriented fibers. Film materials can include single-layer or multi-layer materials.

[0205] Looking at it now Figure 14 An exemplary system in relation to the buffer device according to this disclosure will now be described, as well as how to use it.

[0206] System 1400 includes a film dispensing device 1410 that outputs film material 1415 at a constant or substantially constant speed. The dispensing device 1410 may, for example, include a roll of film material positioned on an air chuck and a servo motor for controlling the output speed.

[0207] System 1400 also includes a buffer device 1500 adapted to receive film material dispensed from film dispensing device 1410 at a constant speed and to output film material at a variable speed. The average value of this variable speed is the same as the constant speed, but includes lower and higher speeds during a single extraction operation iteration.

[0208] The system also includes a thin film extraction device 1420 adapted to extract thin film material at a variable speed. In some embodiments, extracting the thin film material includes repetitive indexing movements, each indexing movement including rapid acceleration followed by rapid deceleration, the indexing movements including complete stops, with a minimum speed lower than a constant speed and a maximum speed higher than a constant speed.

[0209] For example, Figure 14The film extraction device 1420 includes four flat surfaces rotatable about an axis. A single indexing motion extracts approximately one surface of the film from the buffer device 1500. After extraction from the buffer device 1500, the film extraction device stops or continues feeding at a very low speed and cuts the film from a continuous roll into discrete sheets using the cutting assembly 1425. In some embodiments, the cutting assembly 1425 is part of the film extraction device, while in others it is a separate device.

[0210] Figure 14 The system shown can be used in battery manufacturing. In some embodiments, the thin film material 1415 can be a separator material intended to be placed between alternating anode and cathode layers in a battery stack. However, this disclosure is not limited to separator materials; it can be used for any other thin film material that is fed at a constant rate from a thin film dispensing device while being extracted at a variable rate.

[0211] Looking at it now Figure 15 An embodiment of the buffer device 1500 according to the present disclosure will now be described.

[0212] The buffer device 1500 includes a first conveying portion 1510, a second conveying portion 1520, and a buffer portion 1530 located between the first conveying portion and the second conveying portion. In some embodiments, the first conveying portion may include a curved portion 1512 that connects to the flat portion 1514. In some embodiments, the second conveying portion may include a curved portion 1522 and a flat portion 1524.

[0213] In some embodiments, the first conveying section and the second conveying section have identical structures, but their positions are mirror images of each other. In some embodiments, the first conveying section and the second conveying section may have different dimensions. These sections may differ in both size and shape. In embodiments that include curved and flat sections, the dimensions of one or both of the curved and flat sections may differ between the first and second conveying sections. The primary reason for the differences in size, shape, and angle between the first and second conveying sections is due to the position and angle of the systems in which they operate, including leading and following devices (e.g., film dispensing devices and film extraction devices).

[0214] The first conveying section 1510 is adapted to convey the film material at a constant speed, and the second conveying section 1520 is adapted to convey the film material at a variable speed. In other words, the buffer device 1500 is adapted to allow the film material to travel through the conveying sections at different speeds. Neither of the conveying sections needs to include any components for actually conveying the film material on its own.

[0215] In some embodiments, both the first and second conveying sections include air bearings, and the buffer section 1530 includes a suction member that pulls the film toward the bottom 1535 of the buffer section 1530. This suction mechanism, combined with a film dispensing device 1410 that dispenses the film at a constant speed, keeps the film material under tension and maintains its flow toward the bottom 1535 of the buffer section 1530 while traveling through the air bearings of the first conveying section.

[0216] Due to the suction provided by the suction component, the amount of film material on each side of the buffer section is approximately the same. When the film is extracted from the buffer section 1530, this means that the amount of film material on the flat portion of the conveying section will be reduced by approximately half the amount of film material extracted.

[0217] By employing air bearings as the surface on which the thin film material is conveyed through the first and / or second conveying sections, the cushioning device may contain no moving parts or may contain very few moving parts. Having no moving parts or very few moving parts is advantageous for robust systems that are not easily affected by wear and tear.

[0218] Then, the film extraction device 1420 pulls the film material provided in the buffer section and extracts the amount of film to be cut into discrete sheets. Typically, when there is enough film material to be pulled in the buffer section, the film extraction device 1420 pulls the film, but the film material is not pulled above a predetermined level 1550. If the film material is pulled above the predetermined level 1550, it may cause interference in the system.

[0219] In some embodiments, the time between extraction operations can be between 0.1 seconds and 2 seconds, meaning that the time for one indexing movement is less than or equal to this time. In some embodiments, the time is approximately 1 second. In some embodiments, the time is approximately 0.5 seconds. In some embodiments, the time is approximately 0.2 seconds. This means that the time to extract the length of a sheet of film material is the same or less.

[0220] In some embodiments, the buffer portion of the buffer device is adapted to contain 1.5 to 3 times the amount of film material extracted by the film extraction device in a single extraction operation.

[0221] In some embodiments, the buffer device 1500 further includes a measuring device 1540, such as a laser. The measuring device 1540 is adapted to measure the position of the film material in the buffer section 1530 when pulled towards the bottom 1535 of the buffer section 1530 by the suction member and / or when pulled by the film extraction device. By determining the position of the film material at the buffer section, a feedback loop can be established, and either of these speeds can be adjusted if there is a difference between the constant delivery speed of the film material output from the film dispensing device 1410 and the average speed of the variable speed at which the film extraction device extracts the film. If a difference exists, this indicates that the position of the film at the start of the extraction operation is different between subsequent extraction operations. In some embodiments, the speed of the film extraction device is always the same, and the speed of the film dispensing device is adjusted only when a difference occurs.

[0222] As will be understood, if the constant speed at which the film dispensing device 1410 dispenses the film is altered due to this difference, the speed before and after such adjustment is not entirely constant. However, the speed remains constant throughout a particular extraction operation, and it also remains substantially constant over time. In some embodiments, when the feed speed of the film extraction device is adjusted, the adjustment ranges from 0% to 2%, preferably less than 1%, and more preferably only a few tenths of a percent.

[0223] The suction component on the bottom 1535 of the buffer device 1500 can be provided by a vacuum source. The vacuum source can be located outside the buffer device itself, as long as the vacuum source is physically connected to the buffer device 1500. In some embodiments, the buffer device 1500 may therefore include a vacuum port 1560 adapted to provide a vacuum to achieve suction at and toward the bottom 1535 of the buffer device 1500.

[0224] Furthermore, in embodiments where one or both conveying sections 1510, 1520 include air bearings, the buffer device 1500 may include an air supply section 1570 for supplying air to the air bearings. The first and second conveying sections 1510, 1520 may also include cavities for supplying pressurized air to both the rounded and flat portions.

[0225] The purpose of the conveying sections 1510 and 1520 is to enable the film material to be transferred to the film extraction device with low friction and low inertia, preferably with no friction or inertia, or at least substantially no inertia or friction.

[0226] In some embodiments where the conveying section includes an air bearing, the air bearing is made of a porous material that allows air to be supplied through the pores in the material, thereby forming an air bearing that conveys a thin film thereon.

[0227] In some embodiments, the buffer device 1500 further includes an adjusting member 1580 for adjusting the angle and / or position of the first conveying portion and / or the second conveying portion. In some embodiments, the first conveying portion 1510 has one associated adjusting member 1580, and the second conveying portion has another associated adjusting member 1580. In some embodiments, the same adjusting member 1580 is used to adjust the two conveying portions such that they can be adjusted independently or simultaneously. Embodiments in which one or both conveying portions include both flat and curved portions (e.g., Figure 15 In the embodiment shown, the adjusting member 1580 can be used to adjust the flat portion in combination with or independently of the curved portion.

[0228] Looking at it now Figure 16 This diagram shows a view of the film material 1415 being conveyed through the buffer device 1500. As previously described, the film material 1415 is pulled toward the bottom 1535 of the buffer portion 1530 of the buffer device, and a measuring device is measuring the position of the film material. In embodiments where the suction component includes a vacuum, Figure 16 A vacuum will exist below the film at level 1610 shown. As will be understood, because the position of the film material 1415 changes as the system operates, the area below which the vacuum exists will constantly change during operation, but each extraction operation follows the same or substantially the same pattern.

[0229] Looking at it now Figure 17 This illustration shows half of a buffer device 1500 according to one embodiment, which includes a first conveying portion 1510. As will be understood, in embodiments with identical conveying portion structures, Figure 17 The second conveying section 1520 may also be shown. In some embodiments, a vacuum channel 1710 may be provided at the bottom 1535 of the buffer device 1500, the vacuum channel being adapted to provide suction at the bottom 1535 of the buffer section 1530 of the buffer device. The vacuum channel 1710 may include a plurality of holes to provide uniformly distributed suction across the entire buffer section 1530 of the buffer device.

[0230] Looking at it now Figure 18 The steps of a method for transferring thin film material according to one embodiment will now be described. In some embodiments, the method may be performed by the buffer device described herein and / or by the system described herein.

[0231] The method includes transferring film material from a film dispensing device that dispenses film material at a constant speed to a film extraction device that extracts film material through repetitive motion (including rapid acceleration followed by rapid deceleration), the repetitive motion including complete stop.

[0232] The method also includes feeding the thin film material 1802 to a buffer device at a constant rate. The buffer device may be the buffer device described herein.

[0233] The method also includes receiving 1804 film material at a buffer device and providing the film material to a buffer section of the buffer device until the amount of film material at the buffer section is at least the same as the amount required for one film extraction operation.

[0234] In some embodiments, the buffer portion of the buffer device is adapted to maintain the film material under tension. By maintaining the film material under tension, even while it is within the buffer portion, it ensures that the film material is in a suitable position for subsequent extraction. In some embodiments, this means maintaining the film material under tension by suction, which may include a vacuum source.

[0235] In some embodiments, most of the film material is positioned on the surface while in the buffer portion. By positioning the film material on the surface of the buffer portion, it is further ensured that the film material is in a suitable position for subsequent extraction of the film material.

[0236] The method further includes extracting a certain amount of film material from the buffer portion of the buffer device during an extraction operation, the extraction operation including acceleration followed by deceleration. In some embodiments, the extraction operation further includes a complete stop after deceleration.

[0237] In some embodiments, extraction 1806 includes extracting an amount of film material to be cut into individual pieces. In some embodiments, extraction 1806 further includes cutting the film material. In some embodiments, extraction 1806 includes extracting the film with an indexing motion, the indexing motion including rapid acceleration followed by rapid deceleration, the indexing motion including a complete stop after deceleration.

[0238] The foregoing examples are provided for illustrative purposes only and should in no way be construed as limiting the invention disclosed herein. While the invention has been described with reference to various embodiments, it will be understood that the language used herein is descriptive and illustrative, not restrictive. Furthermore, although the invention has been described herein with reference to specific devices, materials, and embodiments, it is not intended to be limited to the specific contents disclosed herein; rather, the invention extends to all functionally equivalent structures, methods, and uses, such as those within the scope of the appended claims. Those skilled in the art, having benefited from the teachings of this specification, can make various modifications thereto, and changes can be made without departing from the scope and spirit of the invention in this respect.

[0239] Any other undisclosed or incidental details regarding the construction or composition of the various elements in the embodiments disclosed in this invention are not considered essential to achieving the advantages of the invention, provided that these elements possess the properties necessary to perform those advantages as disclosed. In view of this disclosure, the selection of these and other construction details is considered entirely within the capabilities of those skilled in the art. Illustrative embodiments of the invention have been described in considerable detail with the aim of disclosing a practical and operable structure that allows for advantageous practice of the invention. The design intent described herein is merely exemplary. Novel features of the invention may be incorporated in other structural forms without departing from the spirit and scope of the invention. The invention covers both embodiments including those described with reference to the illustrative embodiments and embodiments comprising those constituted by such elements. Unless otherwise stated, all common words and terms used herein should be understood in their conventional meaning. All technical terms should have the customary meaning determined by the appropriate technical discipline used by those skilled in the art in that particular field.

Claims

1. A system for stacking diced electrodes in a battery stack, comprising: A first slitting device, the first slitting device having at least three faces, a cutting device and a first buffer device, wherein the first slitting device is configured to slit electrodes from a thin film material; The second slitting device has at least three faces, a cutting device, and a second buffer device, wherein the first slitting device is configured to slit electrodes from the thin film material; A third slitting device, the third slitting device having at least three faces, a cutting device and a third buffer device, wherein the first slitting device is configured to slit electrodes from the thin film material; A first feed conveyor, wherein the first feed conveyor is configured to transport slit electrodes from the first slitting device to the first nest; A second feed conveyor, wherein the second feed conveyor is configured to transport the slit electrodes from the second slitting device to the second nest; A third feed conveyor, wherein the third feed conveyor is configured to transport the slit diaphragm sheet from the third slitting device to the third nest; A conveying device having at least one vacuum-assisted gripping shoe, wherein the conveying device is configured to use the at least one vacuum-assisted gripping shoe to transfer an anode, a cathode, and a diaphragm from the first, second, and third nests of each of a respective first, second, and third feed conveyor to a pickup device. The pickup device is further configured to use one of at least three gripping shoes connected to the pickup device to pick up the anode, the cathode and the diaphragm from the at least one vacuum-assisted gripping shoe of the conveying device; At least one battery stacking station, said at least one battery stacking station being adapted to receive at least one slit anode, at least one slit cathode and at least one slit separator material; Wherein, the at least one battery stacking station is adapted to be located at the battery stacking location and the battery removal location; and A removal device adapted to remove a battery stack from the at least one battery stacking station when the at least one battery stacking station is in a battery removal position.

2. The system according to claim 1, wherein, The conveying device is adapted to alternately transfer the anode and cathode to the rotary pickup device.

3. The system according to claim 1, wherein, The conveying device has a position where the conveying device simultaneously grasps the anode and releases the cathode, and a position where the conveying device simultaneously grasps the cathode and releases the anode.

4. The system of claim 1 further includes a quality inspection device adapted to inspect the cathode, the diaphragm, and the anode before they are transferred to the first nest, the second nest, and the third nest.

5. The system of claim 1 further includes a quality inspection device adapted to inspect the cathode, the diaphragm, and the anode before they are transferred to the pickup device.

6. The system according to claim 1, wherein, Each of the first, second, and third nests further includes an alignment device configured to align the electrode and the diaphragm.

7. The system according to claim 1, wherein, The delivery device includes an alignment device configured to align the electrodes and the diaphragm.

8. The system according to claim 1, wherein, Each of the first nest, the second nest, and the third nest further includes an air bearing, on which the electrode is positioned.

9. The system of claim 1 further includes a second battery stacking station.

10. The system according to claim 9, wherein, The first battery stacking station and the second battery stacking station further include: A vacuum source fluidly connected to the first battery stack station and the second battery stack station, wherein the vacuum source is adapted to apply a suction force around the battery stack.

11. The system according to claim 10, wherein, Each battery stack station is positioned on a mechanical conveyor and is thus adapted to move along at least two axes perpendicular to each other.

12. The system according to claim 10, wherein, Each battery stack station includes movable sidewalls.

13. The system according to claim 1, wherein, The first buffer device, the second buffer device, and the third buffer device are adapted to output a predetermined length of thin film material in a graduated motion manner, wherein the graduated motion includes rapid acceleration followed by rapid deceleration.

14. The system according to claim 1, wherein, The first buffer device, the second buffer device, and the third buffer device further include a suction plate, the suction plate including a vacuum source, the vacuum source being adapted to pull the thin film material toward the suction plate.

15. The system according to claim 1, wherein, The first buffer device, the second buffer device, and the third buffer device further include a measuring device for determining the position of the thin film material.

16. The system according to claim 1, wherein, The first slitting device, the second slitting device, and the third slitting device provide indexing motion including complete cessation of the film material, and cut the film material during the cessation.

17. The system according to claim 1, wherein, The first slitting device, the second slitting device, and the third slitting device, wherein the film material is attached to at least three surfaces of the first slitting device, the second slitting device, and the third slitting device using suction.

18. The system according to claim 1, wherein, The first cutting device, the second cutting device, and the third cutting device are configured to apply different amounts of suction to each of the at least three surfaces.

19. The system according to claim 1, wherein, The cutting device of the first cutting device, the second cutting device and the third cutting device is a blade.

Images