Airflow Electrode Stacking for Fast, Precise Battery Cell Assembly
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Solution Overview
Problem
Existing methods for manufacturing electrode stacks for lithium-ion batteries, such as those using gripper systems, are slow and time-consuming due to the alternating stacking of anodes and cathodes, leading to inefficiencies in the production process.
Innovation Solution
A method and device utilizing an air flow to align and stack anodes and cathodes or monocells within a production area, where the electrodes are conveyed vertically and aligned using airflow generated from opposing sides to achieve precise stacking without mechanical contact, reducing the risk of damage and increasing production speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gripper systems are used to alternately pick up and stack anodes and cathodes, then the electrodes can be precisely positioned and stacked, but the manufacturing process becomes time-consuming and slow
Solution Approach 1:
The patent replaces the mechanical gripper system with an airflow-based system. Air is introduced into the production area to align and stack electrodes without mechanical contact. This substitution eliminates the slow sequential operations of gripper-based picking and placing, enabling parallel processing and significantly increasing manufacturing speed while maintaining stacking precision through controlled airflow patterns.
Solution Approach 2:
The patent employs pneumatic principles by introducing air into the production area to manipulate electrode positioning and stacking. The airflow serves as a non-contact actuator that can simultaneously align multiple electrodes, replacing the mechanical gripper system and enabling faster, parallel operations while maintaining precise stacking through controlled air flow dynamics.
2Reliability
If alternating stacking of anodes and cathodes is performed using conventional methods, then the electrode stack can be manufactured, but the process requires relatively long time
Solution Approach 1:
The patent enables continuous stacking operations by introducing air into the production area, which allows electrodes to be aligned and stacked in a continuous flow rather than through discrete, sequential operations. The airflow continuously acts on multiple electrodes simultaneously, eliminating idle time between stacking operations and significantly reducing total production time while maintaining stacking accuracy.
Solution Approach 2:
The patent performs preliminary alignment of electrodes using airflow before the actual stacking process. By pre-aligning electrodes in the production area using controlled air flow, the system prepares multiple electrodes for simultaneous stacking, eliminating the need for time-consuming sequential positioning and reducing overall production time while ensuring stacking accuracy.
3Ease of operation
If mechanical gripper systems are used for electrode handling, then the electrodes can be transported and stacked, but the risk of electrode damage increases
Solution Approach 1:
The patent replaces mechanical gripper systems with a pneumatic airflow system for electrode handling and stacking. This substitution eliminates mechanical contact that could cause damage to the delicate electrode surfaces, while the airflow provides sufficient control for precise positioning and stacking through non-contact forces.
Solution Approach 2:
The patent introduces air as an intermediary medium between the handling system and the electrodes. This intermediary allows for contactless manipulation of electrodes, eliminating direct mechanical contact that could cause damage while still providing the necessary control forces for accurate positioning and stacking through controlled airflow patterns.
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 method enables rapid and accurate alignment of anodes and cathodes, reducing production time and minimizing damage, while allowing for high throughput and flexibility in electrode stack manufacturing.
Implementation Method 1
an air flow is generated within the production area in such a way that the anodes and cathodes, or the monocells, are aligned with each other and/or with respect to a target position
Implementation Method 2
the anodes and cathodes, or alternatively the mono cells, sink toward the floor due to gravity
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The invention relates to a method for producing an electrode stack (4) from anodes (6) and cathodes (8) for a lithium-ion battery, in particular of an electrically driven motor vehicle, wherein the anodes (6) and the cathodes (8) or a plurality of monocells (10), each of which having one of the anodes (6) and one of the cathodes (8), are conveyed into a production region (14), wherein the anodes (6) and the cathodes (8) or the monocells (10) are conveyed into the production region spaced apart in the vertical direction (Z) from a floor (18) of the production region (14) such that the anodes (6) and the cathodes (8) or the monocells (10) lower to the floor (18), wherein an airflow (L) is generated within the production region (14) by introduction of air, and wherein the anodes (6) and the cathodes (8) or the monocells (10) are oriented toward each other during the course of their lowering by means of the airflow (L). The invention further relates to an apparatus (2) for producing an electrode stack (4) of this kind.