Adhesive Separator Folding for Stable Z-Stacked Electrode Assembly

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Solution Overview

Problem

Conventional Z-folding type electrode assemblies in battery cells face issues with electrodes displacing from their fixed positions due to lack of adequate adhesive strength and separate stacking alignment processes that increase thickness and hinder heat transfer.

Innovation Solution

An apparatus and method for manufacturing electrode assemblies that utilize a separator supply unit, tensioners, and adhesive application to ensure electrodes are securely stacked in a zigzag configuration with adhesive layers between the electrodes and separator sheet, preventing displacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate stacking alignment process is performed to prevent electrode displacement, then electrode position stability is improved, but the overall thickness of the stacked body increases and heat transfer is hindered

Engineering Contradiction:

Improveelectrode position stabilityVSAvoidoverall thickness of stacked body

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The patent merges the stacking and alignment processes into a single integrated operation. The separator sheet is designed with adhesive properties that enable electrodes to be stacked and aligned simultaneously without requiring a separate alignment step, thereby preventing electrode displacement while avoiding increased thickness

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The separator sheet acts as an intermediary element between electrodes. By incorporating adhesive functionality into the separator sheet itself, it mediates the bonding between electrodes and maintains their positional stability without requiring additional alignment structures or processes that would increase overall thickness

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a separate stacking alignment process is performed to prevent electrode displacement, then electrode position stability is improved, but adhesive strength is lowered

Engineering Contradiction:

Improveelectrode position stabilityVSAvoidadhesive strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent combines the alignment function with the adhesive bonding function in a single process step. The separator sheet's adhesive layer bonds electrodes to their designated positions during stacking, achieving both alignment and strong adhesion simultaneously without the need for separate processes that would compromise adhesive strength

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If electrodes are stacked without adhesive application to maintain simplicity, then manufacturing complexity is reduced, but electrode position stability deteriorates

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidelectrode position stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The separator sheet is designed with multi-functionality, serving both as the physical separator between electrodes and as the adhesive bonding medium. This universal component eliminates the need for separate adhesive application steps while ensuring electrode position stability, thereby maintaining manufacturing simplicity without sacrificing reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If the separator sheet material has low inherent adhesive strength to maintain material simplicity, then material selection is simplified, but electrode position stability deteriorates

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidelectrode position stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The separator sheet is constructed as a composite material structure, combining the base separator material with an adhesive layer. This composite design provides both the functional properties of the separator material and the bonding properties of the adhesive, ensuring electrode position stability while allowing flexibility in material selection for different application requirements

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively maintains electrode position within the assembly, enhances adhesive strength, and improves heat transfer while maintaining efficient battery performance.

Implementation Method 1

an adhesive layer formed between each of the electrodes and the separator sheet

Methodology Applied

Scientific EffectAdhesive: Adhesive

Data Source

PatentUS20260074294A1Electrode Assembly Comprising Adhesive on Separator Sheet and Apparatus and Method for Manufacturing the Same

Publication Date: 2026.03.12 LG ENERGY SOLUTION LTD

AI summary

An apparatus for manufacturing an electrode assembly includes a separator supply unit, table, separator guide, first adhesive supply unit, and pair of tensioners. The separator supply unit is configured for supplying a separator sheet from which a separator is formed. The table is configured for supporting electrodes and sections of the separator sheet. The separator guide is configured for guiding the separator sheet to fold in a particular folding direction. The first adhesive supply unit is configured for applying an adhesive to portions of the separator sheet and the electrodes supported by the table. The pair of tensioners are each configured for pressing an uppermost section of the separator sheet guided by the separator guide against the table or against a placed electrode that directly underlies the uppermost section. The electrode assembly is manufactured by a process using the apparatus.