Accumulator Cell Stacking Wheels for Precise Sheet Alignment
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Solution Overview
Problem
Existing methods for producing lithium-ion accumulators face inefficiencies in the stacking process, particularly in the automation and alignment of anode, cathode, and separator materials, leading to potential misalignment and the need for additional fixing steps.
Innovation Solution
A fully automated stacking device with a conveyor line, distributor unit, and stacking wheels arranges anode, cathode, and separator sheets in a predetermined sequence to form cell stacks, using a distributor roller and gripper mechanism to ensure precise alignment and continuous feeding, followed by a continuous furnace for immediate fixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual or semi-automated stacking methods are used for assembling accumulator cells, then device complexity is reduced, but manufacturing precision and alignment quality deteriorate
Solution Approach 1:
The patent replaces manual mechanical stacking operations with an automated stacking device that uses a conveyor line, distributor unit, and stacking wheels. This mechanical substitution enables precise alignment and consistent positioning of accumulator cells without manual intervention, directly resolving the contradiction between manufacturing precision and device complexity.
2Productivity
If discontinuous stacking processes are used, then device complexity is reduced, but productivity deteriorates
Solution Approach 1:
The patent implements a continuous stacking process where the conveyor line continuously transports accumulator cells through the stacking device. The distributor unit and stacking wheels operate continuously to assemble cells into packs without interruption, eliminating idle time and significantly improving productivity compared to discontinuous batch processes.
3Manufacturing precision
If adhesive tapes are used for fixing cell stacks, then manufacturing precision is improved, but loss of substance increases due to additional materials
Solution Approach 1:
The patent extracts and eliminates the adhesive tape fixing step from the stacking process. Instead of using adhesive tapes to secure cell stacks, the continuous stacking device mechanically assembles and positions cells with precise alignment, achieving stack stability through the stacking mechanism itself rather than through additional fixing materials.
4Manufacturing precision
If multiple fixing steps are used to secure cell stacks, then manufacturing precision is improved, but loss of time increases due to additional processing steps
Solution Approach 1:
The patent merges the alignment and fixing operations into a single continuous stacking action. The stacking device simultaneously positions and secures accumulator cells in their final positions without requiring separate fixing steps, thereby maintaining manufacturing precision while eliminating time-consuming sequential operations.
Data Source
AI summary
A method for producing accumulators which each have at least one cell stack, wherein to produce the cell stack, individual sheets are stacked via a stacking device in that the individual sheets are fed one after the other via a conveying line of the stacking device to a stacking wheel arrangement of the stacking device. The stacking wheel arrangement has two stacking wheels which are arranged in two planes one above the other. A predefined number of successive individual sheets are fed to one of the two stacking wheels. The predefined number corresponds to the number of individual sheets in a finished cell stack. A plurality of the individual sheets following the predefined number of individual sheets are fed to the other of the two stacking wheels.