Apparatus and method for manufacturing internal assemblies

Abstract

The present invention provides a manufacturing apparatus and method for internal assemblies. [Solution] A coupling unit comprising a movable frame that can move along a forming trajectory between a first position and a second position, and a forming support mounted on the movable frame, wherein the coupling unit is configured to form an inner assembly by coupling a web on the forming support in an overlapping layer structure while the movable frame is moving between the first position and the second position, and an unloading mechanism configured to pick up the inner assembly from the forming support while the movable frame is moving between the first position and the second position, and to release the inner assembly in a predetermined release area spaced apart from the movable frame, comprising a gripping device configured to grip and hold the inner assembly, and a moving device configured to move the gripping device in the same direction and at substantially the same speed as the movable frame while the gripping device is gripping the inner assembly.

Description

Technical Field

[0001] The present invention relates to an apparatus for manufacturing an inner assembly and a method therefor.

Background Art

[0002] Within the scope of this specification and the appended claims, "inner assembly" means an object formed by at least one web, or more webs laminated to each other and / or wound around a forming support.

[0003] The present invention finds a preferred, but not exclusive, application in the field of manufacturing electrochemical cells of, for example, cylindrical or prismatic type. For its realization, an inner assembly having an overlapping layer structure formed by webs wound in the form of a reel or by means of the z-folding technique is manufactured.

[0004] The type of inner assembly referred to in this specification is formed on a forming support onto which one or more webs are fed.

[0005] For example, cylindrical electrochemical cells, and certain types of prismatic electrochemical cells, are formed by two electrode webs (a positive electrode and a negative electrode, respectively) laminated alternately to each other and two separator webs, whereby one of the two separator webs is interposed between the two electrode webs, fed onto a rotatable forming support, and wound around it to form an inner assembly for an electrolytic cell. Each electrode web is composed of a conductive sheet coated with a positive electrode active material or a negative electrode active material, respectively. Each separator web is instead composed of a layer of dielectric material.

[0006] The inner assembly can have various shapes depending on the shape of the forming support on which it is formed. For example, a rotatable forming support, generally shaped like a pin, leads to the winding of an inner assembly having a substantially circular cross-section, for example, for the creation of a cylindrical electrochemical cell. A rotatable forming support, shaped like a plate, leads to the winding of an inner assembly having, for example, an elliptical, elongated, or flattened cross-section, for the creation of a prismatic electrochemical cell.

[0007] In the case of an inner assembly formed by wound-up webs, to form the inner assembly, multiple webs are fed from a feeding unit, for example by unwinding from their respective parent reels, joined together by overlapping them, wound onto a forming support, and then the wound-up webs are cut to form the inner assembly. The webs may be overlapped upstream of the forming support and fed to the forming support as a single multilayer web, or they may be fed to the forming support individually and joined during winding.

[0008] After the inner assembly is formed, any known finishing operations can be performed. For example, each rolled web has a free flap that can be secured, for example, by applying an adhesive patch. Subsequently, the forming support is withdrawn, and the inner assembly is released. [Overview of the project] [Problems that the invention aims to solve]

[0009] The applicant has preliminary observed how the web advance rate relative to the forming support can constitute a critical limiting factor in manufacturing capacity in situations where improving the performance and efficiency of the manufacturing process is always necessary. This limitation is even more critical when high precision is required in the formation of the inner assembly. In particular, the applicant has noted that in many applications, such as the manufacture of electrochemical cells, high precision in the geometric shape of the inner assembly must be ensured to guarantee the required performance of the finished product.

[0010] The applicant noted that any interruption and resumption of the advancement of at least one web would result in an undesirable decrease in manufacturing efficiency, as well as increased wear on moving parts that undergo increased acceleration and deceleration in an attempt to compensate for these negative fluctuations in productivity.

[0011] Therefore, the applicant has found that by arranging one or more forming supports on a movable frame that moves relative to the feeding unit during web feeding and formation of the inner assembly, it is possible to simplify web feeding, for example, by maintaining a substantially constant speed and / or feeding direction from the feeding unit, and thus improve manufacturing efficiency.

[0012] The applicant observed that, in order to carry out manufacturing cycles of successive inner assemblies, it is necessary to remove the inner assemblies produced during a manufacturing cycle from the forming support so that the forming support can be used for a new manufacturing cycle.

[0013] The applicant noted that the removal of the inner assembly from the forming support should be performed without impairing the manufacturing efficiency of the device.

[0014] The applicant recognized that if the inner assembly could be removed from the forming support without impairing, or substantially altering, the movement of the movable frame during web winding, the forming support could be made available for a new manufacturing cycle without impairing the manufacturing efficiency of the apparatus.

[0015] The applicant has found that by holding the inner assembly while the movable frame is moving and removing the forming support from the inner assembly while the inner assembly is held, the forming support can be made available for a new manufacturing cycle without impairing the manufacturing efficiency of the apparatus. [Means for solving the problem]

[0016] Therefore, in its first embodiment, the present invention relates to an apparatus for manufacturing an inner assembly for an electrochemical cell, preferably for the manufacture of a battery.

[0017] Preferably, a movable frame is provided. The movable frame is movable along a forming trajectory between a first position and a second position spaced apart from the first position.

[0018] Preferably, a coupling unit is provided. The coupling unit comprises at least one forming support mounted on the movable frame.

[0019] Preferably, the coupling unit is configured to form an inner assembly by coupling at least one web in an overlapping layer structure onto the forming support while the movable frame is moving between a first position and a second position, preferably at least partially.

[0020] Preferably, an unloading mechanism is provided. The unloading mechanism is preferably configured to remove the inner assembly from the forming support while the movable frame is moving between a first position and a second position, at least partially.

[0021] Preferably, the unloading mechanism is configured to release the inner assembly in a predetermined release area spaced apart from the movable frame.

[0022] Preferably, the unloading mechanism comprises a gripping device configured to grip and hold the inner assembly.

[0023] Preferably, the unloading mechanism includes a moving device configured to move the gripping device at substantially the same speed and in the same direction as the movable frame while at least the gripping device is gripping the inner assembly.

[0024] In its second aspect, the present invention preferably relates to a method for manufacturing an inner assembly for an electrochemical cell, preferably for the manufacture of a battery.

[0025] Preferably, a movable frame is provided to move between a first position and a second position spaced from the first position.

[0026] Preferably, at least one web is bonded in an overlapping layer structure onto a forming support mounted on the movable frame, preferably while at least partially the movable frame is moving between the first position and the second position, to form an inner assembly.

[0027] Preferably, the inner assembly is lifted from the forming support while the movable frame is moving between the first position and the second position.

[0028] Preferably, lifting the inner assembly includes gripping the inner assembly by a gripping device and simultaneously moving the gripping device at substantially the same speed and in the same direction as the movable frame.

[0029] Preferably, holding the inner assembly by the gripping device is provided at least partially while moving the gripping device to a predefined release area spaced from the movable frame.

[0030] Preferably, the gripping device is moved towards a predefined release area spaced from the movable frame and simultaneously the inner assembly is held by the gripping device.

[0031] Preferably, the inner assembly is released in the release area.

[0032] Moving the movable frame during the feeding of at least one web makes it possible to change the feeding speed and / or destination direction and / or destination position of at least one web to the forming support without substantially changing the speed of the web in the feeding unit.

[0033] The unloading mechanism unloads the inner assembly formed on the forming support in a predetermined release area without requiring the movable frame to be stopped, and in the release area, subsequent processing can be performed on the inner assembly.

[0034] To unload the inner assembly while the movable frame is moving, the moving device moves the gripping device so as to cancel out the relative velocity between the gripping device and the inner assembly while the gripping device is gripping the inner assembly.

[0035] The movable frame is movable between a first position and a second position. The first and second positions are spaced apart along the longitudinal direction. Terms such as "longitudinal direction" and "in the longitudinal direction" are used in relation to a direction parallel to the longitudinal direction or a quantity measured parallel to the longitudinal direction.

[0036] "The first longitudinal direction" refers to the longitudinal direction oriented from the first position to the second position.

[0037] "Second longitudinal direction" refers to the longitudinal direction directed from the second position to the first position.

[0038] The forming support extends along the principal transverse direction. If the bonding unit is configured to wind at least one web around the forming support by rotating the forming support around a pivot axis, the pivot axis coincides with the principal transverse direction. The principal transverse direction is perpendicular to the longitudinal direction.

[0039] Terms such as "transverse direction" or "in the transverse direction" are used in reference to quantities measured in a direction parallel to the primary transverse direction or parallel to the primary transverse direction.

[0040] The term "web" means an object having a first thickness dimension, a second width dimension at least one order of magnitude, preferably at least two orders of magnitude, greater than the first dimension, and a third length dimension at least one order of magnitude, preferably at least two orders of magnitude, greater than the second dimension. Such an object is flexible in at least the third length dimension so that it can be rolled up or folded on a forming support. A web can be made from a single sheet of material or from multiple sheets that have been pre-layered and joined together.

[0041] When referring to two elements and saying they "cancel each other's relative motion," it means modifying, adapting, or controlling the motion of one of the two elements so that it moves at substantially the same speed and in the same direction as the other element, or so that it remains stationary when the other element is also stationary.

[0042] In one or both embodiments, the present invention may have at least one of the preferred features described below. Such features may exist individually or in combination with each other in both the apparatus and the method of the present invention, unless otherwise specified.

[0043] Preferably, a feeding unit is provided which is configured to feed the at least one web to the coupling unit along each feeding path.

[0044] Preferably, the at least one web is provided to be fed from the feeding unit along each feeding path.

[0045] Preferably, the at least one web includes multiple webs, and more preferably four webs.

[0046] Preferably, the feeding unit is configured to feed multiple webs along each feeding path.

[0047] Preferably, the movable frame is movable between the first position and the second position relative to the feeding unit.

[0048] Preferably, the first position of the movable frame is located near the feeding unit.

[0049] Preferably, the second position of the movable frame is distal to the feeding unit.

[0050] Preferably, the feeding unit is configured to feed four webs along each feeding path.

[0051] Preferably, feeding at least one web from the feeding unit along a feeding path includes feeding multiple webs, preferably four webs, along each feeding path.

[0052] Preferably, the plurality of webs include a first electrode web, a second electrode web, and two separator webs.

[0053] In an alternative embodiment, the at least one web described above is a multilayer web composed of multiple overlapping layers.

[0054] Preferably, the plurality of layers include a first electrode layer, a second electrode layer, and two separator layers.

[0055] Preferably, the feeding unit is configured to feed the stacked webs onto the forming support.

[0056] Preferably, feeding the plurality of webs includes feeding the webs, which are stacked on top of each other, onto the forming support.

[0057] Preferably, the feeding unit is configured to feed the webs onto the forming support in such a state that two separator webs are alternately arranged with two electrode webs.

[0058] Preferably, feeding the plurality of webs includes feeding the webs onto the forming support such that two separator webs are alternately arranged with two electrode webs.

[0059] Preferably, a fixed frame is provided.

[0060] Preferably, the feeding unit is fixedly mounted to the fixed frame.

[0061] Preferably, the movable frame is movable between a first position and a second position relative to the fixed frame.

[0062] Preferably, the movable frame is slidable between a first position and a second position relative to the fixed frame.

[0063] Preferably, the movable frame is longitudinally movable between a first position and a second position.

[0064] Preferably, the movable frame is movable in the first longitudinal direction from a first position to a second position.

[0065] Preferably, moving the movable frame from a second position toward a first position includes moving the movable frame in a first longitudinal direction.

[0066] Preferably, the movable frame is movable from a first position to a second position for at least a certain amount of time at a speed substantially equal to the feeding speed of the at least one web.

[0067] Preferably, the movable frame is movable in the second longitudinal direction from a second position to a first position.

[0068] Preferably, the movable frame is provided to be moved from a second position toward a first position.

[0069] Preferably, moving the movable frame from a second position toward a first position includes moving the movable frame in a second longitudinal direction.

[0070] Preferably, the second longitudinal direction is opposite to the first longitudinal direction.

[0071] Preferably, the at least one web is fed along the feeding path by moving the web in a direction having a direct component as a first longitudinal direction.

[0072] Preferably, each web is fed along the feeding path by moving the web in a direction having a direct component as a first longitudinal direction.

[0073] Preferably, the movable frame is movable alternately between a first position and a second position in a first longitudinal direction and a second longitudinal direction.

[0074] Preferably, the movable frame is provided to be moved alternately between a first position and a second position in a first longitudinal direction and a second longitudinal direction.

[0075] Preferably, the direction of movement of the movable frame is reversed at the first position.

[0076] Preferably, the movable frame is provided to be stopped in the first position for a substantially zero time interval.

[0077] Preferably, the direction of movement of the movable frame is reversed at the second position.

[0078] Preferably, the movable frame is provided to be stopped in the second position for a substantially zero time interval.

[0079] Preferably, the forming support comprises a first pin extending in the transverse direction.

[0080] Preferably, the forming support comprises a second pin extending in the transverse direction.

[0081] Preferably, one end of the at least one web is provided to be positioned at the interface between the first pin and the second pin.

[0082] Preferably, the coupling unit comprises at least one winding device mounted on the movable frame and configured to wind the at least one web around the at least one forming support.

[0083] Preferably, the method provided involves winding the at least one web around the at least one forming support.

[0084] Preferably, the winding device is configured to rotate the forming support around a transverse winding axis.

[0085] Preferably, winding up the at least one web preferably involves rotating the forming support around a transverse winding axis.

[0086] Preferably, the coupling unit includes a withdrawal mechanism configured to withdraw the forming support from the inner assembly.

[0087] Preferably, the forming support is provided to be withdrawn from the inner assembly.

[0088] Preferably, the withdrawal mechanism is configured to withdraw the forming support from the inner assembly while the movable frame is moving at least partially between the first and second positions.

[0089] Preferably, the removal of the forming support from the inner assembly is performed at least partially while moving the movable frame between the first and second positions.

[0090] Preferably, the winding shaft is in the transverse direction.

[0091] Preferably, at least a first pin is moved transversely to pull the forming support out of the inner assembly.

[0092] Preferably, the first pin, followed by the second pin, is moved transversely to withdraw the forming support from the inner assembly.

[0093] Preferably, the extraction mechanism is configured to move the first pin and the second pin independently in the transverse direction.

[0094] Preferably, withdrawing the forming support from the inner assembly involves moving the first pin, and then the second pin, in the transverse direction.

[0095] Preferably, the movable frame is configured to move from a second position to a first position while winding the at least one web-forming support around the support.

[0096] Preferably, the movable frame is moved from a second position to a first position while winding the at least one web around the forming support.

[0097] Preferably, the withdrawal mechanism is configured to withdraw the forming support from the inner assembly while the movable frame is moving in the first longitudinal direction toward a second position and / or while the movable frame is substantially in the second position and / or while the movable frame is moving in the second longitudinal direction toward a first position.

[0098] Preferably, the withdrawal mechanism is configured to initiate the withdrawal of the forming support from the inner assembly at a distance from the second position that is less than 70%, preferably less than 40%, and more preferably less than 30%, of the distance between the second position and the first position, as the movable frame moves from the first position to the second position.

[0099] Preferably, the withdrawal mechanism is configured to complete the withdrawal of the forming support from the inner assembly when the movable frame is substantially in the second position.

[0100] Preferably, the withdrawal mechanism is configured to complete the withdrawal of the forming support from the inner assembly when the movable frame is at a distance from the second position of less than 30%, preferably less than 20%, and more preferably less than 10% of the distance between the second position and the first position.

[0101] Preferably, the forming support is provided to be withdrawn from the inner assembly while the movable frame is moving toward a second position in the first longitudinal direction, and / or while the movable frame is in the second position, and / or while the movable frame is moving from the second position toward the first position.

[0102] Preferably, when the movable frame moves from the first position to the second position, the withdrawal of the forming support from the inner assembly is initiated at a distance from the second position that is less than 70%, preferably less than 40%, and more preferably less than 30% of the distance between the second position and the first position.

[0103] Preferably, withdrawing the forming support from the inner assembly includes completing the withdrawal of the forming support from the inner assembly when the movable frame is substantially in the second position.

[0104] Preferably, the withdrawal of the forming support from the inner assembly is provided when the movable frame is at a distance from the second position of less than 30%, preferably less than 20%, and more preferably less than 10% of the distance between the second position and the first position.

[0105] Preferably, the gripping device is configured to hold the inner assembly at least partially while the extraction mechanism extracts the forming support from the inner assembly.

[0106] Preferably, the gripping device is provided to hold the inner assembly, at least partially, during the withdrawal of the forming support from the inner assembly.

[0107] Preferably, the moving device is configured to move the gripping device at substantially the same speed and in the same direction as the movable frame while the gripping device is holding the inner assembly.

[0108] Preferably, the moving device is configured to move the gripping device at substantially the same speed and in the same direction as the movable frame while the extraction mechanism extracts the forming support from the inner assembly.

[0109] Preferably, the gripping device is provided to move substantially at the same speed and in the same direction as the movable frame while the gripping device is holding the inner assembly.

[0110] Preferably, the gripping device is moved at substantially the same speed and in the same direction as the movable frame while the forming support is being withdrawn from the inner assembly.

[0111] Preferably, the moving device is configured to at least partially cancel out the longitudinal relative motion between the gripping device and the forming support while the extraction mechanism is pulling the forming support out of the inner assembly.

[0112] Preferably, the longitudinal relative motion between the gripping device and the forming support is compensated for, at least partially, during the withdrawal of the forming support from the inner assembly.

[0113] Preferably, the moving device is mounted on the fixed frame.

[0114] Preferably, the moving device is configured to move the gripping device at substantially the same speed and in the same direction as the movable frame while the movable frame transitions from a second position.

[0115] Preferably, the ability to move the gripping device at substantially the same speed and in the same direction as the movable frame is provided while the movable frame transitions from a second position.

[0116] In this way, while the gripping device grips the inner assembly, there is virtually no relative movement between the gripping device and the inner assembly.

[0117] Preferably, the ability to move the gripping device at substantially the same speed and in the same direction as the movable frame is provided at least partially during the withdrawal of the forming support from the inner assembly.

[0118] Preferably, the moving device is configured to move the gripping device at substantially the same longitudinal speed and in the same direction as the forming support while the extraction mechanism is extracting the forming support from the inner assembly.

[0119] Preferably, the movement of the gripping device is provided at substantially the same longitudinal speed and in the same longitudinal direction as the forming support while at least partially withdrawing the forming support from the inner assembly.

[0120] In an alternative embodiment, the moving device is mounted on the movable frame.

[0121] Preferably, the moving device is configured to keep the gripping device substantially stationary relative to the movable frame while the extraction mechanism extracts the forming support from the inner assembly.

[0122] Preferably, the ability to keep the gripping device substantially stationary relative to the movable frame is provided at least partially while the forming support is withdrawn from the inner assembly.

[0123] Preferably, the moving device is configured to move the gripping device at substantially the same speed and substantially in the opposite direction to the forming support while at least partially the gripping device is releasing the inner assembly.

[0124] Preferably, the ability to move the gripping device substantially in the opposite direction at substantially the same speed as the forming support is provided at least partially while releasing the inner assembly.

[0125] In this way, while the gripping device is releasing the inner assembly, there is virtually no relative movement between the inner assembly and the predetermined release area.

[0126] Preferably, the predetermined open area is defined on the fixed frame.

[0127] Preferably, the gripping device is configured to grip the inner assembly while the movable frame is moving from a first position to a second position.

[0128] Preferably, gripping the inner assembly by the gripping device is provided while the movable frame is moving from a first position to a second position.

[0129] Preferably, the withdrawal mechanism is configured to begin withdrawing the forming support from the inner assembly while the movable frame is moving from a first position to a second position.

[0130] Preferably, the forming support is to begin to be withdrawn from the inner assembly while the movable frame is moving from a first position to a second position.

[0131] In one embodiment, the withdrawal mechanism is configured to complete the withdrawal of the forming support from the inner assembly while the movable frame is moving from a second position to a first position.

[0132] In one embodiment, the completion of the withdrawal of the forming support from the inner assembly is provided while the movable frame moves from a second position to a first position.

[0133] Preferably, the moving mechanism is configured to move the gripping device away from the movable frame toward the release area after the forming support has been withdrawn from the inner assembly and while the gripping device is at least partially holding the inner assembly.

[0134] Preferably, moving the gripping device toward a predetermined release area separated from the movable frame is performed after withdrawing the forming support from the inner assembly.

[0135] In an alternative embodiment, the unloading mechanism includes a retaining member mounted on the movable frame.

[0136] Preferably, the retaining member is configured to hold the inner assembly at least partially while the extraction mechanism extracts the forming support from the inner assembly.

[0137] Preferably, the gripping device is configured to grip the inner assembly while the inner assembly is held by the retaining member.

[0138] Preferably, the retaining member is clamp-shaped.

[0139] Preferably, the inner assembly is held in place by a retaining member, at least partially mounted on the movable frame, while the forming support is being withdrawn from the inner assembly.

[0140] Preferably, holding the inner assembly while the forming support is withdrawn from the inner assembly by a retaining member at least partially mounted on the movable frame includes clamping the inner assembly with the retaining member.

[0141] Preferably, the retaining member is movable between a retaining configuration configured to hold the inner assembly wound around the forming support and a disengagement configuration configured not to hold the inner assembly wound around the forming support.

[0142] Preferably, retaining the inner assembly includes moving the retaining member from the disengagement configuration to the retaining configuration.

[0143] Preferably, the holding member comprises a first arm that is hinged to the movable frame and has a gripping portion.

[0144] Preferably, the holding member comprises a second arm that is hinged to the movable frame and has a gripping portion.

[0145] Preferably, at least one of the first arm and the second arm is rotatable to move the retaining member from a disengaged configuration to a retaining configuration by bringing their respective gripping portions closer together.

[0146] Preferably, both the first arm and the second arm are rotatable to move the retaining member from the disengagement configuration to the retaining configuration.

[0147] Preferably, at least one of the first arm and the second arm is rotatable to move the retaining member from a retaining configuration to a disengaged configuration by separating their respective gripping portions from each other.

[0148] Preferably, both the first arm and the second arm are rotatable to move the retaining member from the retaining configuration to the disengagement configuration.

[0149] Preferably, holding the inner assembly involves bringing the gripping portions of the retaining member closer together until they contact the outer surface of the inner assembly.

[0150] Preferably, bringing the respective gripping portions closer together includes rotating a first arm that has one of the gripping portions, and / or rotating a second arm that has the other gripping portion.

[0151] Preferably, rotating the first arm and rotating the second arm includes rotating the first arm and the second arm in opposite directions to each other.

[0152] Preferably, the first arm is rotatable about a first axis of rotation.

[0153] Preferably, the first arm includes a radial portion that extends radially with respect to the first axis of rotation.

[0154] Preferably, the first arm includes a transverse portion that extends in the transverse direction.

[0155] Preferably, the first arm includes an arc-shaped portion that extends circumferentially with respect to the first axis of rotation.

[0156] Preferably, the first arm extends from a first end to a second end.

[0157] Preferably, the first arm is hinged to the movable frame at its first end.

[0158] Preferably, the radial portion extends from the first end.

[0159] Preferably, the gripping portion of the first arm is located at the second end.

[0160] Preferably, the arc-shaped portion extends from the second end.

[0161] Preferably, the transverse portion extends from the radial portion to the arched portion.

[0162] Preferably, the second arm is rotatable about a second axis of rotation.

[0163] Preferably, the second arm includes a radial portion that extends radially with respect to the second axis of rotation.

[0164] Preferably, the second arm includes a transverse portion that extends in the transverse direction.

[0165] Preferably, the second arm includes an arc-shaped portion that extends circumferentially with respect to the second axis of rotation.

[0166] Preferably, the second arm extends from the first end to the second end.

[0167] Preferably, the second arm is hinged to the movable frame at its first end.

[0168] Preferably, the radial portion extends from the first end.

[0169] Preferably, the gripping portion of the second arm is located at the second end.

[0170] Preferably, the arc-shaped portion extends from the second end.

[0171] Preferably, the transverse portion extends from the radial portion to the arched portion.

[0172] Preferably, the gripping portion has a concave surface that is opposite in shape to the outer surface of the inner assembly.

[0173] Preferably, the holding of the inner assembly begins while the movable frame moves from the first position to the second position.

[0174] Preferably, the holding of the inner assembly begins while the movable frame moves from the first position to the second position.

[0175] Preferably, the withdrawal of the forming support from the inner assembly is initiated while the movable frame moves from the first position to the second position.

[0176] Preferably, the inner assembly described above is provided to be released.

[0177] Preferably, releasing the inner assembly includes moving the retaining member from the retaining configuration to the disengaged configuration.

[0178] Preferably, the inner assembly is provided to be released from the retaining member.

[0179] Preferably, the inner assembly is released while the movable frame moves from the second position to the first position.

[0180] In one embodiment, the withdrawal of the forming support from the inner assembly is completed while the movable frame moves from a first position to a second position.

[0181] In one embodiment, the withdrawal of the forming support from the inner assembly is completed while the movable frame moves from a first position to a second position.

[0182] In one embodiment, the withdrawal of the forming support from the inner assembly is completed while the movable frame moves from the second position to the first position.

[0183] Preferably, the release of the inner assembly is performed after the formation support has been completely withdrawn from the inner assembly.

[0184] Preferably, a movable support is provided that is mounted on a movable frame.

[0185] Preferably, at least one of the winding devices is mounted on the movable support.

[0186] Preferably, the at least one forming support is mounted on the movable support.

[0187] Preferably, the movable support is configured to move the at least one forming support between a winding position and an unloading position relative to the movable frame.

[0188] Preferably, at least two forming supports are provided, mounted on the movable support.

[0189] Preferably, at least three forming supports are provided, mounted on the movable support.

[0190] Preferably, when one of the forming supports is in the winding position, the other forming support is in the unloading position.

[0191] Preferably, the movable support is configured to move the at least one forming support between a winding position, a finishing position, and an unloading position relative to the movable frame.

[0192] Preferably, when one of the forming supports is in the winding position, the other forming support is in the finishing position.

[0193] Preferably, the at least one winding device is configured to wind the at least one web around each forming support at the winding position.

[0194] Preferably, the withdrawal mechanism is configured to withdraw the forming support from the inner assembly in the unloaded position.

[0195] Preferably, the retaining member is configured to hold the inner assembly in the unloaded position.

[0196] Preferably, the apparatus is configured to perform a finishing operation on the inner assembly at the finishing position.

[0197] Preferably, the apparatus is configured to cut the at least one web at the finishing position.

[0198] Preferably, the mobile device is mounted directly onto the fixed frame.

[0199] Preferably, the moving device is mounted on the fixed frame independently of the movable frame.

[0200] Preferably, the gripping device is configured to grip the inner assembly while the inner assembly is at least partially held by the retaining member.

[0201] Preferably, gripping the inner assembly by the gripping device is provided while the inner assembly is at least partially held by the retaining member.

[0202] Preferably, the retaining member is configured to release the inner assembly after the gripping device has gripped the inner assembly.

[0203] Preferably, the release of the inner assembly from the retaining member is provided after the inner assembly has been gripped by the gripping device.

[0204] Preferably, the retaining member is configured to release the inner assembly after the forming support has been withdrawn from the inner assembly.

[0205] Preferably, the retaining member is configured to release the inner assembly while the movable frame moves from the second position to the first position.

[0206] Preferably, the retaining member is configured to release the inner assembly when the movable frame is at a distance from the second position of less than 30%, preferably less than 20%, more preferably less than 10%, and even more preferably less than 5% of the distance between the second position and the first position.

[0207] Preferably, the moving device is configured to move the gripping device in synchronization with the movable frame.

[0208] Preferably, the moving device is configured to move the gripping device at substantially the same speed and in the same direction as the movable frame while the gripping device grips the inner assembly held by the retaining member.

[0209] Preferably, the moving device is configured to move the gripping device at substantially the same speed and in the same direction as the movable frame until the retaining member releases the inner assembly, while the gripping device is gripping the inner assembly held by the retaining member.

[0210] Preferably, the moving device is configured to move the inner assembly to a predetermined release area.

[0211] Preferably, the inner assembly is released when the movable frame is at a distance from the second position of less than 30%, preferably less than 20%, more preferably less than 10%, and even more preferably less than 5% of the distance between the second position and the first position.

[0212] Preferably, gripping the inner assembly involves moving the gripping device in synchronization with the movable frame.

[0213] Preferably, gripping the inner assembly involves moving the gripping device at substantially the same speed and in the same direction as the movable frame while the gripping device is gripping the inner assembly and until the retaining member releases the inner assembly.

[0214] Preferably, the moving device is configured to move the gripping device toward the release area while the gripping device is at least partially holding the inner assembly and after the extraction mechanism has completed the extraction of the forming support from the inner assembly.

[0215] Preferably, the unloading mechanism is configured to begin moving the gripping device toward the release area while the movable frame is moving from the second position toward the first position.

[0216] Preferably, the forming support comprises at least one first pin extending in the transverse direction, and the extraction mechanism is configured to move the at least one first pin in the transverse direction.

[0217] Preferably, the gripping device is configured to grip the inner assembly at the unloaded position of each forming support.

[0218] Preferably, the moving device comprises an articulated arm having two axes. Preferably, the two axes are oriented in the transverse direction.

[0219] Preferably, the moving device comprises two gripping portions that are movable toward and away from each other.

[0220] Preferably, the gripping portion is configured to contact the cylindrical outer surface of the inner assembly.

[0221] Preferably, the gripping portions are movable relative to each other by pure translation.

[0222] Preferably, the gripping portions are movable relative to each other without rotating with respect to each other.

[0223] Preferably, the articulated arm comprises a first end and a second end, the articulated arm being attached to the fixed frame at the first end, and the gripping device being attached to the articulated arm at the second end.

[0224] Further features and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, provided as exemplary and non-limiting examples with reference to the accompanying drawings. [Brief explanation of the drawing]

[0225] [Figure 1] This is a schematic diagram of an apparatus for manufacturing an internal assembly according to the present invention. [Figure 1A] This is a schematic diagram of an apparatus for manufacturing an internal assembly according to a different embodiment of the present invention. [Figure 2] This is a perspective view of the apparatus for manufacturing an internal assembly according to the present invention in different operating configurations, with some elements removed to highlight other elements. [Figure 3] This is a perspective view of the apparatus for manufacturing an internal assembly according to the present invention in different operating configurations, with some elements removed to highlight other elements. [Figure 4] This is a perspective view of the apparatus for manufacturing an internal assembly according to the present invention in different operating configurations, with some elements removed to highlight other elements. [Figure 5] This is a perspective view of the apparatus for manufacturing an internal assembly according to the present invention in different operating configurations, with some elements removed to highlight other elements. [Figure 6]This is a perspective view of the apparatus for manufacturing an internal assembly according to the present invention in different operating configurations, with some elements removed to highlight other elements. [Figure 7] This is a detailed diagram of the device in Figure 1 in different operating configurations. [Figure 8] This is a detailed diagram of the device in Figure 1 in different operating configurations. [Figure 9] This is a detailed diagram of the device in Figure 1 in different operating configurations. [Figure 10] This is a detailed diagram of the device in Figure 1 in different operating configurations. [Figure 11] This is a detailed diagram of the device in Figure 1 in different operating configurations. [Figure 12] This is a perspective view of an apparatus for manufacturing an internal assembly according to different embodiments of the present invention in different operating configurations, with some elements removed to highlight other elements. [Figure 13] This is a perspective view of an apparatus for manufacturing an internal assembly according to different embodiments of the present invention in different operating configurations, with some elements removed to highlight other elements. [Modes for carrying out the invention]

[0226] The representations in the attached drawings do not necessarily need to be understood in terms of scale, nor do they necessarily take into account the proportions between various parts.

[0227] Figure 1 schematically illustrates the apparatus for manufacturing the internal assembly, which is shown as a whole with reference number 100.

[0228] Apparatus 100 is for the manufacture of an inner assembly 1 consisting of at least one wound web. In a preferred example illustrated and described in detail herein, apparatus 100 is for the manufacture of an inner assembly 1 used in the fabrication of an electrochemical cell. However, as discussed above, the present invention may find applications in other types of inner assemblies that are not necessarily for the fabrication of electrochemical cells.

[0229] In a preferred embodiment as illustrated in Figure 1, assembly 1 is made up of a plurality of webs N1, N2, N3, and N4. For example, when the inner assembly 1 is used in a situation to make an electrochemical cell, the webs may be formed by electrode webs N1, N3 and separator webs N2, N4. These webs N1, N2, N3, and N4 are appropriately stacked to realize a layered structure in which first electrode webs (e.g., precursors for the positive electrode of the electrochemical cell), first separator webs, second electrode webs (e.g., precursors for the negative electrode of the electrochemical cell), and second separator webs alternate with each other. The order between the first electrode webs and second electrode webs is provided for illustrative purposes only, and the reverse order of the order shown above may also be provided.

[0230] The apparatus 100 includes a feeding unit 110, schematically illustrated in Figure 1. The feeding unit 110 is configured to feed webs N1, N2, N3, and N4 along their respective feeding paths P1, P2, P3, and P4. In a preferred embodiment, the feeding unit 110 is fixedly mounted to a fixed frame 101 of the apparatus 100.

[0231] Webs N1, N2, N3, and N4 move along their respective feeding paths P1, P2, P3, and P4, each having a longitudinal component oriented in the same direction.

[0232] In the illustrated example, the feeding unit 110 includes a web distribution device 111 which may be a reel support configured to unwind the webs N1, N2, N3, N4 from large reels B1, B2, B3, B4 and subsequently feed them during the operation of the device 100. The distribution device 111 may further include respective actuators (not shown) adapted to rotate the reels B1, B2, B3, B4 about their respective axes of rotation.

[0233] Without loss of generality, further processing and / or movement steps of webs N1, N2, N3, and N4 can be provided between unwinding and feeding along their respective feeding paths P1, P2, P3, and P4.

[0234] This specification and Figure 1 refer to a particular case of a feeding unit 110 configured to unwind and feed four webs N1, N2, N3, and N4 of a type suitable for the manufacture of electrolytic cells, but the feeding unit can be configured to feed a single web along each feeding path, or even more than four webs along each feeding path. In further embodiments, one or more webs may be made of materials different from the electrode webs and separator webs described above, and are not further limited to the manufacture of electrolytic cells.

[0235] Where, in the remainder of this specification, features and components of the apparatus 100 are described with reference to the four webs N1, N2, N3, and N4 of the embodiment in Figure 1, these features or components may be adapted, without loss of generality, to perform the same functions as described when the inner assembly 1 is made from a single web or a number of different webs.

[0236] The apparatus 100 includes a movable frame 120. The movable frame 120 is movable relative to the feeding unit 110. In particular, the movable frame 120 is slidably mounted relative to the fixed frame 101 of the apparatus 100. The movable frame 120 is movable relative to the feeding unit 110 along a forming trajectory between a first position and a second position. The first and second positions are separated longitudinally. In the first position, the movable frame 120 is closer to the feeding unit 110 than in the second position.

[0237] The forming trajectory can have various shapes. In the illustrated preferred embodiment, the movable frame 120 is configured to move linearly between a first position and a second position. The movable frame 120 is configured to move from the first position to the second position, and then alternately from the second position to the first position, preferably without substantially stopping. The movable frame 120 is movable from the first position to the second position in a first longitudinal direction D1 oriented away from the feeding unit 110. The longitudinal components of the feeding direction of the webs N1, N2, N3, N4 along their respective feeding paths P1, P2, P3, P4 are oriented in the first longitudinal direction D1. The speed at which the movable frame moves from the first position to the second position is substantially equal to the feeding speed of the webs N1, N2, N3, N4.

[0238] The movable frame 120 is further movable from the second position to the first position in a second longitudinal direction D2 oriented toward the feeding unit 110. The second longitudinal direction D2 is opposite to the respective longitudinal components of the feeding direction of the webs N1, N2, N3, and N4 along their respective feeding paths P1, P2, P3, and P4.

[0239] A sliding guide (not shown) may be provided between the movable frame 120 and the fixed frame 101 to guide the sliding of the movable frame 120 relative to the fixed frame. The device 100 may further provide one or more actuators (not shown) for moving the movable frame 120 between a first position and a second position.

[0240] The movable support 125 is attached to the movable frame 120, and the movable support 125 is shown in Figures 2 to 6, but is omitted from the schematic Figure 1 for simplification. In a preferred embodiment, the movable support 125 includes a wheel 126 rotatably mounted on the movable frame 120. The wheel 126 is rotatable about a rotation axis R. The rotation axis R is oriented in the transverse direction. An actuator (not shown) is provided for rotating the movable support 125 relative to the movable frame 120.

[0241] The coupling unit 128 is configured to join webs N1, N2, N3, and N4 together.

[0242] The coupling unit 128 comprises at least one forming support 130 attached to the movable frame 120. Preferably, the coupling unit 128 comprises a plurality of forming supports 130. In the embodiments illustrated in Figures 2 to 10, the coupling unit 128 comprises three forming supports 130. In embodiments not shown, the coupling unit 128 may comprise a single forming support 130 or a number of forming supports 130 other than three.

[0243] Preferably, the forming support 130 is attached to the movable support 125. The movable support 125 is configured to move each forming support 130 between a winding position, a finishing position, and an unloading section relative to the movable frame 120. In the embodiments illustrated in Figures 2 to 10, the winding position, the finishing position, and the unloading section are arranged on the movable frame 120 along a circular track, at angles to each other and spaced apart. Preferably, the winding position, the finishing position, and the unloading position are equidistant from each other at angles.

[0244] The movable support 125 is configured to sequentially move each forming support 130 from the winding position to the finishing position, from the finishing position to the unloading position, and from the unloading position to the winding position. In the illustrated embodiment, the movable support 125 is configured to keep each forming support 130 fixed or substantially fixed to the movable frame 120 when the movable frame 120 moves from a first position to a second position, and when the movable frame 120 moves from a second position to a first position.

[0245] In the embodiments illustrated in Figures 2 to 10, the movable support 125 is configured to move each forming support 130 between two consecutive positions, a winding position, a finishing position, and an unloading portion, while the movable frame 120 is moving from a first position to a second position. Preferably, the movable support 125 is configured to complete the movement of each forming support 130 between the two consecutive positions before the movable frame 120 reaches the second position. In a preferred embodiment, the movable support 125 is configured to move each forming support 130 between the two consecutive positions by rotating by a predetermined angle about a rotation axis R. In the illustrated embodiment, the predetermined angle is equal to the angle that moves the two consecutive forming supports 130 away from the rotation axis R, for example, 120°.

[0246] The forming support 130 is movable relative to the fixed frame 101 along a movement path determined by the movement of the movable frame 120 between the second position and the first position, and the movement of the support frame 125 between the winding position, the finishing position, and the unloading portion.

[0247] For each forming support 130, a winding device 135 is mounted on a movable frame 120. In the embodiment illustrated in Figures 2 to 10, three winding devices 135 are provided. Each winding device 135 is configured to rotate each forming support 130 around a transverse winding axis A. Each winding device includes a rotary actuator 136.

[0248] The coupling unit 128 is configured to continuously transport at least one end of the webs N1, N2, N3, and N4 on each forming support 130. The forming support 130 is driven by a winding device 135 and rotates around a winding axis A to wind up the webs N1, N2, N3, and N4 and form the inner assembly 1.

[0249] The forming support 130, illustrated in detail in Figure 11, comprises a first pin 137 extending transversely and a second pin 138 extending transversely and aligned with the first pin 137. The forming support 130 is configured to engage with and hold at least one of the webs N1, N2, N3, and N4 at the interface 139 between the first pin 137 and the second pin 138.

[0250] The extraction mechanism 140 is configured to extract the forming support 130 from the inner assembly 1 formed around the forming support 130. The extraction mechanism 140 is configured to move the first pin 137 and the second pin 138 independently in the transverse direction. The extraction mechanism 140 is configured to move the first pin 137 and the second pin 138 from their respective operating positions to their respective non-operating positions. In the operating position, the first pin 137 and the second pin 138 are configured to engage with at least one of the webs N1, N2, N3, and N4 to form the inner assembly 1. In the non-operating position, the first pin 137 and the second pin 138 are configured not to engage with the webs N1, N2, N3, and N4. Preferably, the forming support 130 has a tapered shape to facilitate its extraction. At least one of the first pin 137 and the second pin 138 has a tapered shape. Preferably, the interface 139 extends along a plane inclined with respect to the transverse direction to facilitate the withdrawal of the forming support 130. To facilitate the withdrawal of the forming support 130, the withdrawal mechanism 140 is configured to initiate the withdrawal of the first pin 137, and then, after a predetermined time interval, to initiate the withdrawal of the second pin 138.

[0251] In embodiments not shown, the forming support 130 may have different shapes known to itself. For example, if the apparatus 100 is configured to produce a prismatic type electrolytic cell, the forming support 130 may have a plate-like shape. In embodiments not shown, the forming support 130 may be monolithic.

[0252] The inner assembly 1 is formed around the forming support 130 in a manner known to itself by rotating the forming support 130 around a winding shaft while at least one of the webs N1, N2, N3, and N4 is held in place. At least one of the held webs is inserted into the interface 139 between the first pin 137 and the second pin 138.

[0253] Each forming device 130 is configured to receive the webs N1, N2, N3, and N4 at their respective winding positions. A feeding member (not shown) is configured to feed the webs N1, N2, N3, and N4 to the forming support 130 in a manner known by itself, thereby allowing the forming support 130 to receive at least one of the webs N1, N2, N3, and N4 between the first pin 137 and the second pin 138.

[0254] The winding device 135 is configured to wind the webs N1, N2, N3, and N4 around the forming support 130 while the movable frame 120 is moving from a second position to a first position and while the forming support 130 is in the winding position.

[0255] As the webs N1, N2, N3, and N4 are wound up, the inner assembly 1 is positioned along the respective feeding paths P1, P2, P3, and P4, and is still joined to the portions of the webs N1, N2, N3, and N4 coming from the feeding unit 110, forming around the forming support 130. The support frame 125 is preferably configured to move the forming support 130, around which the inner assembly 1 is formed, from the winding position to the finishing position while the movable frame 120 moves from a first position to a second position.

[0256] A cutting member (not shown) is configured to cut the webs N1, N2, N3, and N4 in a manner known by itself, thereby separating the inner assembly 1 from the portions of the webs N1, N2, N3, and N4 positioned along their respective feeding paths P1, P2, P3, and P4. In the illustrated embodiment, the cutting of the webs N1, N2, N3, and N4 is performed when the forming support 130 around which the inner assembly 1 is wound is in the finishing position.

[0257] Further finishing members, known in themselves and not shown, can be provided to perform finishing work on the inner assembly 1 while each forming support 130 is in the finishing position. For example, one end of the web portion constituting the inner assembly 1 may be fixed by attaching an adhesive patch to the outer surface of the inner assembly 1.

[0258] The apparatus 100 is configured to perform cutting and finishing of the inner assembly 1 while the movable frame 120 moves from a first position to a second position and / or thereafter from the second position to the first position.

[0259] The forming supports 130, together with the inner assembly 1 formed around each forming support 130, are movable from the finished position to the unloaded position after the finishing operation, preferably while the movable frame 120 is moving from the first position to the second position.

[0260] The apparatus 1 includes an unloading mechanism 145 configured to pick up the inner assembly 1 from each forming support 130 and transfer the inner assembly 1 to a predetermined release area 146 separated from the movable frame.

[0261] In the first embodiment illustrated in Figures 1 and 2 to 11, the unloading mechanism 145 includes a retaining member 150 mounted on the movable frame 120. The retaining member 150 is configured to hold the inner assembly 1 while each forming support 130 is being pulled out by the extraction mechanism 140. In the illustrated embodiment, the retaining member 150 is clamp-shaped.

[0262] The retaining member 150 comprises a first arm 151 hinged to a mounting support 152 fixedly mounted on the movable frame 120. The mounting support 152 is mounted on the movable frame in close proximity to the movable support 125. The first arm 151 is rotatable relative to the movable frame 120 about a first transverse axis of rotation R1. Preferably, the first arm 151 is made as a single block without joints. The first arm 151 extends from a first end 153 to a second end 154. At the first end 153, the first arm 151 is hinged to the mounting support 152. At the second end 154, the first arm 151 comprises a gripping portion 155 configured to contact the inner assembly 1. The gripping portion 155 comprises a concave surface 156. The concave surface 156 is shaped opposite to the cylindrical outer surface portion of the inner assembly 1.

[0263] The first arm 151 includes a radial portion 157 extending radially from a first end 153 with respect to a first axis of rotation R1. The first arm 151 further includes an arc-shaped portion 158 extending substantially circumferentially from a gripping portion 155 with respect to the first axis of rotation R1. The first arm 151 further includes a transverse portion 159 extending substantially transversely between the arc-shaped portion 158 and the radial portion 157 to transversely offset the gripping portion 155 from the radial portion 157.

[0264] The retaining member 150 includes a second arm 161 hinged to a mounting support 152. The second arm 161 is rotatable relative to the movable frame 120 about a second transverse axis of rotation R2. Preferably, the second arm 161 is made as a single block without joints. The second arm 161 extends from a first end 163 to a second end 164. At the first end 163, the second arm 161 is hinged to the mounting support 152, preferably adjacent to the first end 153 of the first arm 151. At the second end 164, the second arm 161 includes a gripping portion 165 configured to contact the inner assembly 1. The gripping portion 165 includes a concave surface 166. The concave surface 166 is shaped opposite to the cylindrical outer surface portion of the inner assembly 1. The concave surface 166 of the gripping portion 165 of the second arm 161 faces the concave surface 156 of the gripping portion 155 of the first arm 151.

[0265] The second arm 161 includes a radial portion 167 extending radially from the first end 163 with respect to the second axis of rotation R2. The second arm 161 further includes an arc-shaped portion 168 extending substantially circumferentially from the gripping portion 165 with respect to the second axis of rotation R2. The second arm 161 further includes a transverse portion 169 extending substantially transversely between the arc-shaped portion 168 and the radial portion 167 to transversely offset the gripping portion 165 from the radial portion 167.

[0266] The retaining member 150 is movable between the retaining configuration and the disengagement configuration. The retaining member 150 is movable between the retaining configuration and the disengagement configuration by the rotation of the first arm 151 around the first rotation axis R1 and the rotation of the second arm 161 in opposite directions around the second rotation axis R2. In the illustrated embodiment, the first arm 151 rotates clockwise from the retaining configuration to the disengagement configuration and counterclockwise from the disengagement configuration to the retaining configuration. The second arm 161 rotates counterclockwise from the retaining configuration to the disengagement configuration and clockwise from the disengagement configuration to the retaining configuration.

[0267] In the holding configuration, the gripping portion 155 of the first arm 151 and the gripping portion 165 of the second arm 161 are in contact with the inner assembly 1, which is wound onto the forming support 130 of the winding device 135, on both sides of the inner assembly 1 in the unloaded position. The holding member 150 is configured to press the gripping portions 155 and 165 against the inner assembly 1 with sufficient force to hold the inner assembly 1 in a fixed position relative to the movable support 120 while the forming support 130 is being pulled out from the inner assembly 1.

[0268] In the disengagement configuration, the gripping portion 155 of the first arm 151 and the gripping portion 165 of the second arm 161 are spaced further apart from each other than in the holding configuration, and are configured not to engage with the inner assembly 1 wound onto the forming support 130 of the winding device 135 in the unload position, or are movable from the finishing position to the unload position without holding the inner assembly.

[0269] The retaining member 150 is configured to move in a retaining configuration while the movable frame 120 moves from a first position to a second position, gripping the inner assembly 1, which is wound around the forming support 130 of the winding device 135, in the unloaded position. The withdrawal mechanism 140 is configured to withdraw the forming support 130 from the inner assembly 1 while the inner assembly 1 is held by the retaining member 150. This can occur before the movable frame 120 reaches the second position, while the movable frame 120 is in the second position, or while the movable frame 120 is moving from the second position to the first position. Withdrawal of the forming support 130 can begin while the movable frame 120 is moving from the first position to the second position and can end while the movable frame 120 is still moving from the first position to the second position, while the movable frame is substantially in the second position, or while the movable frame 120 has already moved from the second position to the first position.

[0270] The unloading mechanism 145 includes a moving device 170. The moving device 170 is mounted on a fixed frame 101. The moving device 170 is mounted on the movable frame 120 on the side opposite to the feeding unit 110. The movable frame 120 moves closer to the moving device 170 by moving from a first position to a second position, and moves away from the moving device 170 by moving from the second position to the first position.

[0271] The mobile device 170 preferably includes an articulated robot arm 171 having two degrees of freedom. The articulated arm 171 extends from a first end 172 to a second end 173, to which the articulated arm 171 is fixedly attached to the fixed frame 101.

[0272] The unloading mechanism 145 preferably includes a gripping device 175 attached to a moving device 170 at a second end 173. The moving device 170 is configured to move the gripping device 175 longitudinally by the joint movement of an articulated arm 171.

[0273] The gripping device 175 comprises two gripping portions 176, the gripping portions being movable toward and away from each other between a gripping configuration in which the gripping portions 176 are configured to grip and hold the inner assembly 1 between the gripping portions, and a release configuration in which the gripping portions 176 are configured to release the inner assembly 1. In the illustrated embodiment, the gripping portions 176 are movable toward each other only by translation, without rotation toward each other.

[0274] In the first embodiment, the gripping device 175 is configured to grip the inner assembly 1 while the inner assembly 1 is held by the retaining member 150. The retaining member 150 is configured to move from a retaining configuration to a disengaging configuration, for example, after the moving device 170 grips the inner assembly 1 when the movable frame 120 is substantially in a second position, or while the movable frame 120 is moving from a second position to a first position.

[0275] The gripping device 175 is configured to grip the inner assembly 1 while the inner assembly 1 is held by the retaining member 150. The gripping device 175 is configured to engage with portions of the outer surface of the inner assembly that are not engaged by the gripping portions 155, 165 of the retaining member 150. In the illustrated embodiment, the gripping device 175 is configured to engage with each peripheral band on the outer surface of the inner assembly 1. The gripping portions 155, 165 of the retaining member 150 are configured to engage with the central band on the outer surface of the inner assembly 1, which is positioned between the peripheral bands.

[0276] While the gripping device 175 grips the inner assembly 1, before the holding device 150 releases the inner assembly 1, the moving device 170 is configured to move the gripping device 175 to hold the inner assembly 1, thereby canceling out the relative movement between the gripping device 175 and the inner assembly 1 (and therefore between the gripping device 175 and the holding member 150). The moving device 170 is configured to keep the gripping device 175 moving at substantially the same speed and in the same direction as the inner assembly 1 (and therefore at substantially the same speed and in the same direction as the movable frame 120). In the illustrated embodiment, this movement is achieved by the articulation of the articulated arm 171.

[0277] After releasing the inner assembly 1 from the holding member 150, the moving device 170 is configured to move the inner assembly 1, which is held by the gripping device 175, toward a predetermined release area 146, thereby releasing the inner assembly 1 into the release area 146.

[0278] To manufacture the internal assembly 1 of the type described above, according to a first embodiment of the apparatus 100, the movable frame 120 is moved from a second position to a first position, performing a first stroke of the movable frame 120. While the movable frame 120 is moving from the second position to the first position, at least one web, preferably a plurality of webs N1, N2, N3, N4, are fed to the forming support 130. While the movable frame 120 is moving from the second position to the first position, the plurality of webs N1, N2, N3, N4 are wound around the forming support 130, causing the forming support 130 to rotate around the winding axis A. When winding is complete, the rotation of the forming support 130 is stopped.

[0279] Next, the movable frame 120 is moved from the first position to the second position, performing a second stroke of the movable frame 120. Preferably, the stopping time of the movable frame 120 in the first position is substantially zero.

[0280] During the second stroke, the webs N1, N2, N3, and N4 are separated from the web portions wound around the forming support 130 and cut along the feeding paths P1, P2, P3, and P4 to form the inner assembly 1 from the web portions.

[0281] Next, the movable frame 120 is moved from the second position to the first position and performs a third stroke of the movable frame 120, similar to the first stroke. Preferably, the stopping time of the movable frame 120 in the second position is substantially zero.

[0282] While the movable frame 120 moves from the first position to the second position, the forming support 130, around which the webs N1, N2, N3, and N4 have been wound during the first stroke, moves from the winding position to the finishing position. This movement preferably ends before the movable frame 120 reaches the second position.

[0283] During the third stroke of the movable frame 120, the webs N1, N2, N3, N4 are wound onto a further forming support 130 to initiate the manufacture of a further inner assembly (not shown), the manufacture being carried out in a manner similar to the method described for the inner assembly 1. The manufacture of the further inner assembly is time-offset by the time required for the movable frame 120 to stroke from the first position to the second position and from the second position to the first position, and is carried out partially simultaneously with the manufacture described for the inner assembly 1.

[0284] During the second and / or third stroke of the movable frame 120, finishing processes are carried out on the inner assembly 1 wound around the forming support 130 of the winding device 135 in the finishing position.

[0285] Subsequently, the movable frame 120 is moved from the first position to the second position to execute a fourth stroke of the movable frame 120, as illustrated in FIGS. 2-4. During the fourth stroke, the assembly 1 is gripped and held by the holding member 150. To hold the inner assembly 1, the holding member 150 moves from a disengaged configuration to a holding configuration, as illustrated in FIGS. 3, 7, and 8.

[0286] While the movable frame 120 is moving from the first position to the second position, the forming support 130 around which the webs N1, N2, N3, N4 were wound during the first stroke is moved from the finishing position to the unloading position, as illustrated in FIGS. 2, 7, and 8. This movement preferably ends before the movable frame 120 reaches the second position and is carried out in a manner similar to the method described above from the winding position to the finishing position.

[0287] While the movable frame 120 is moving from the first position to the second position and while the assembly 1 is held by the holding member 150, the forming support 130 is withdrawn from the inner assembly 1, as illustrated in FIGS. 4 and 9.

[0288] Subsequently, the movable frame 120 is moved from the second position to the first position, and as illustrated in FIGS. 5 and 6, a fifth stroke of the movable frame 120 is executed similar to the first and third strokes. Preferably, the stopping time of the movable frame 120 at the second position is substantially zero. The pulling out of the forming support 130 from the inner assembly 1 may end before the end of the fourth stroke, substantially at or near the second position, or at the start of the fifth stroke.

[0289] While the inner assembly 1 is held by the holding member 150, the inner assembly 1 is gripped as illustrated in FIGS. 5 and 9. This may be done before the end of the fourth stroke. The inner assembly 1 is gripped by the gripping device 175. To grip the inner assembly 1, the gripping device 175 is brought to the inner assembly 1, and the gripping device 175 is maintained at the inner assembly 1 for the time required for gripping, and the relative movement between the gripping device 175 and the inner assembly 1 is canceled. To keep the gripping device 175 at the inner assembly 1, the gripping device 175 is moved by the articulated arm 171 at substantially the same speed and in the same direction as the inner assembly 1 (and thus the movable frame 120).

[0290] After the forming support 130 is removed from the inner assembly 1 and after the gripping device 175 grips the inner assembly 1, the inner assembly 1 is released from the holding member 150 as illustrated in FIGS. 6 and 10. To release the inner assembly 1 from the holding member 150, the holding member 150 is preferably moved from the holding configuration to the disengaging configuration during the fifth stroke of the movable frame 120.

[0291] After the inner assembly 1 is released from the holding member 150, the inner assembly 1 held by the gripping device 175 is moved by the moving device 170 to the release area 146, and the inner assembly 1 is released from the gripping device 175.

[0292] In the second embodiment illustrated in Figures 1A, 12, and 13, the apparatus 100 comprises all the elements described with reference to the first embodiment, except for the retaining member 150. The second embodiment is the same as the first embodiment, except for the elements described below.

[0293] In this second embodiment, the gripping device 175 is configured to grip the inner assembly 1 before the withdrawal mechanism 140 withdraws the forming support 130. The gripping device 175 is configured to grip and hold the inner assembly 1 while the movable frame 110 moves from a first position to a second position. The gripping device 175 is configured to grip and hold the assembly 1 by engaging its outer surface. The moving device 170 is configured to move the gripping device 175 so as to keep the gripping device 175 in place of the inner assembly 1, thereby canceling out the relative movement between the gripping device 175 and the inner assembly 1. The moving device 170 is then configured to cancel out the longitudinal relative movement between the gripping device 175 and the forming support 130. To this end, the moving device 170 is configured to keep the gripping device 175 moving at substantially the same speed and in the same direction as the inner assembly 1 (and thus at substantially the same speed and in the same direction as the movable frame 120) while the gripping device 175 is gripping and holding the inner assembly 1. In the illustrated embodiment, this movement is achieved by the articulation of the articulated arm 171.

[0294] The extraction mechanism 140 is configured to extract the forming support 130 from the inner assembly 1 after the gripping device 175 has gripped the inner assembly 1, while the inner assembly 1 is held by the gripping device 175, and while the moving device 170 moves the gripping device 175 at the same speed and in the same direction as the movable frame 120.

[0295] After the forming support 130 is withdrawn from the assembly 1, the moving device 170 is configured to move the gripping device 175 and the inner assembly 1 held by the gripping device 175 toward a predetermined release area 146. The gripping device 175 is configured to hold the inner assembly until it reaches the release area 146, and then release the inner assembly 1 in the release area 146.

[0296] The manufacture of the above-described type of inner assembly 1 according to the second embodiment of apparatus 100 is the same as described above with reference to the first embodiment of apparatus 100 up to the fourth stroke of apparatus 100.

[0297] In the second embodiment, during the fourth stroke, assembly 1 is gripped by the gripping device 175 and held by the gripping device 175 while the movable frame 120 moves from the first position. To grip and hold the inner assembly 1, the gripping device 175 is brought to the inner assembly 1 and is maintained in the inner assembly 1 for the time required to pull out the forming support 130. To keep the gripping device 175 in the inner assembly 1, the relative movement between the gripping device 175 and the inner assembly 1 is offset, and the gripping device 175 is moved by the articulated arm 171 at substantially the same speed and in the same direction as the inner assembly 1 (and thus the movable frame 120).

[0298] While the movable frame 120 moves from the first position to the second position, and while the assembly 1 is held by the gripping device 175, the forming support 130 is withdrawn from the inner assembly 1.

[0299] Next, the movable frame 120 is moved from the second position to the first position, and a fifth stroke of the movable frame 120 is performed, similar to the first and third strokes. Preferably, the stopping time of the movable frame 120 in the second position is substantially zero. The withdrawal of the forming support 130 may be completed before the movable frame 120 reaches the second position, or it may continue while the movable frame has already moved from the second position toward the first position. In the second case, the moving device 170 moves the gripping device 175 in accordance with the reversal of the movement of the movable frame 120.

[0300] After the forming support 130 is withdrawn from the inner assembly 1, the inner assembly 1, held by the gripping device 175, is moved to the release area 146 by the moving device 170, and the inner assembly 1 is released by the gripping device 175.

[0301] According to a modification of the embodiment applicable to both the first and second embodiments described above, the moving device 170 can be mounted on the movable frame 120 instead of the fixed frame 101. In this case, to grip the inner assembly 1, the moving device 170 keeps the gripping device 175 stationary relative to the movable frame 120. In the second embodiment, the moving device 170 keeps the gripping device 175 stationary relative to the movable frame 120 while the forming support 130 is being pulled out from the inner assembly 1 held by the gripping device 175. In this modification of the embodiment, the gripping device 175 is configured to release the inner assembly 1 in the release area 146 while the movable frame 120 is moving from a second position to a first position. The moving device 170 is configured to move the gripping device 175 relative to the movable frame 120 to offset the relative movement between the gripping device 175 and the release area 146, so as to maintain the gripping device 175 in a substantially fixed position relative to the release area 146 while the gripping device 175 releases the inner assembly 1. To maintain the gripping device 175 in a substantially fixed position relative to the release area 146, the moving device moves the gripping device 175 at a speed equal to and in the opposite direction to the movable frame 120.

Claims

1. Preferably, an apparatus (100) for manufacturing an inner assembly for an electrochemical cell for the manufacture of a battery, A movable frame (120) that can move along a forming trajectory between a first position and a second position spaced apart from the first position, A coupling unit (128) comprising at least one forming support (130) mounted on the movable frame (120), wherein the coupling unit (128) is configured to form an inner assembly (1) by bonding at least one web (N1; N2; N3; N4) on the forming support (130) in an overlapping layer structure while at least partially the movable frame (120) is moving between the first position and the second position, An unloading mechanism (145) configured to lift the inner assembly (1) from the forming support (130) and release the inner assembly (1) in a predetermined release area (146) spaced apart from the movable frame (120) while the movable frame (120) is at least partially moving between the first and second positions, comprising: a gripping device (175) configured to grip and hold the inner assembly (1); and a moving device (170) configured to move the gripping device (175) at substantially the same speed and in the same direction as the movable frame (120) while at least the gripping device (175) is gripping the inner assembly (1), A device (100) comprising:

2. The aforementioned coupling unit (128) Mounted on the movable frame (120), at least one winding device (135) configured to wind the at least one web (N1; N2; N3; N4) around the at least one forming support (130), A withdrawal mechanism (140) is configured to withdraw the forming support (130) from the inner assembly (1) while at least partially the movable frame (120) is moving between the first and second positions, The apparatus (100) according to claim 1, comprising:

3. The gripping device (175) is configured to hold the inner assembly (1) at least partially while the extraction mechanism (140) extracts the forming support (130) from the inner assembly (1), The apparatus (100) according to claim 2, wherein the moving device (170) is configured to move the gripping device (175) at substantially the same speed and in the same direction as the movable frame (120) while the withdrawal mechanism (140) withdraws the forming support (130) from the inner assembly (1).

4. The apparatus (100) according to claim 2 or 3, wherein the gripping device (175) is configured to grip the inner assembly while the movable frame (120) is moving from the first position to the second position.

5. The unloading mechanism (145) is movable between a holding configuration in which a holding member (150) mounted on the movable frame (120) is configured to hold the inner assembly wound onto the forming support (130), and a disengagement configuration in which the holding member (150) is configured not to hold the inner assembly (1) wound onto the forming support (130), The extraction mechanism (140) is configured to extract the forming support (130) from the inner assembly (1) while at least partially the retaining member (150) holds the inner assembly (1), The gripping device (175) is configured to grip the inner assembly (1) while the inner assembly (1) is held by the retaining member (150), The apparatus (100) according to claim 2, wherein the moving device (170) is configured to move the gripping device (175) at substantially the same speed and in the same direction as the movable frame (120) while at least the gripping device (175) is gripping the inner assembly (1) held by the retaining member (150).

6. The apparatus (100) according to any one of claims 2 to 5, wherein the withdrawal mechanism (140) is configured to initiate the withdrawal of the forming support (130) from the inner assembly (1) at a distance from the second position that is less than 70%, preferably less than 40%, more preferably less than 30%, of the distance between the first position and the second position when the movable frame (120) moves from the first position to the second position.

7. The apparatus (100) according to any one of claims 2 to 6, wherein the moving device (170) is configured to move the gripping device (175) toward the release area (146) while the gripping device (175) is holding the inner assembly (1) and after the withdrawal mechanism (140) has completed the withdrawal of the forming support (130) from the inner assembly (1).

8. The apparatus (100) according to any one of claims 2 to 7, wherein the moving device (170) is configured to start moving the gripping device (175) toward the release area (146) while the movable frame (120) is moving from the second position toward the first position.

9. The apparatus (100) according to any one of claims 2 to 8, wherein the forming support (130) comprises at least one first pin (137) extending transversely, and the extraction mechanism (140) is configured to move the at least one first pin (137) transversely while at least partially the inner assembly (1) is held by the unloading mechanism (145).

10. The movable frame (120) is equipped with a movable support (125) mounted on it, and the at least one forming support (130) is mounted on the movable support (125), The movable support (125) is configured to move the at least one forming support (130) between a winding position and an unloading position relative to the movable frame (120), The at least one winding device (135) is configured to wind the at least one web around each of the forming supports (130) at the winding position of each forming support (130), The withdrawal mechanism (140) is configured to withdraw the forming support (130) from the inner assembly (1) at the unload position of each of the winding devices. The apparatus (100) according to any one of claims 2 to 9, wherein the gripping device (175) is configured to grip the inner assembly (1) at the unloaded position of each of the forming supports (130).

11. The apparatus (100) according to any one of the preceding claims, wherein the moving device (170) comprises an articulated arm (171).

12. Equipped with a fixed frame (101), The movable frame (120) is movable between the first position and the second position relative to the fixed frame (101), The apparatus according to claim 11, wherein the articulated arm (171) comprises a first end (172) and a second end (173), the articulated arm (171) is attached to the fixed frame (101) at the first end (172), and the gripping device (175) is attached to the articulated arm (171) at the second end (173).

13. The apparatus (100) according to any one of the preceding claims, comprising a feeding unit (110) configured to feed the at least one web (N1; N2; N3; N4) along a feeding path (P1; P2; P3; P4), wherein the first position of the movable frame (120) is proximal to the feeding unit (110) and the second position of the movable frame (120) is distal to the feeding unit (110).

14. Preferably a method for manufacturing an inner assembly for an electrochemical cell for the manufacture of a battery, The movable frame (120) is moved between a first position and a second position spaced apart from the first position, At least partially while the movable frame (120) is moving between the first and second positions, at least one web (N1; N2; N3; N4) is joined in an overlapping layer structure on a forming support (130) mounted on the movable frame (120) to form an inner assembly (1), The picking up of the inner assembly (1) from the forming support (130) while the movable frame (120) is moving between the first position and the second position, wherein the picking up of the inner assembly (1) includes gripping the inner assembly (1) with a gripping device (175) and simultaneously moving the gripping device (175) at substantially the same speed and in the same direction as the movable frame (120). The gripping device (175) is moved toward a predetermined release area (146) separated from the movable frame (120), and at the same time the inner assembly (1) is held by the gripping device (175), The inner assembly (1) is released in the release area (146), Methods that include...

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