Anode-Free Cell Stacking Fold for Thin Collector Handling
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Solution Overview
Problem
The existing methods for manufacturing anode-free cells face challenges in handling and cutting thin sheets, which can lead to deformation, damage, and improper stacking, resulting in inefficiencies and increased costs.
Innovation Solution
The proposed solution involves creating an anode-free cell with a continuous laminated separator-current collector-separator layer, which is laminated between pairs of separators and cathode layers in a continuous stacking fold, allowing for reduced handling and efficient cutting of the anode current collector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thin sheets of anode current collector are handled and cut using existing methods, then the cell can be assembled, but the thin sheets undergo deformation and damage leading to improper stacking
Solution Approach 1:
The patent combines the anode current collector with separator layers to form a single laminated structure. This merging eliminates the need to handle and cut thin anode current collector sheets separately, preventing deformation and damage while ensuring proper stacking alignment in the assembled cell.
Solution Approach 2:
The anode current collector is pre-laminated with separator layers before assembly. This preliminary action of combining components prevents the thin sheets from being subjected to harmful handling and cutting operations during the assembly process, thereby maintaining manufacturing precision and preventing damage.
2Ease of manufacture
If thin sheets of anode current collector are handled extensively, then the cell can be assembled, but the handling time increases and costs increase
Solution Approach 1:
By merging the anode current collector with separator layers into a laminated structure, the number of separate handling operations is reduced. This simplifies the assembly process and significantly decreases handling time, making manufacturing more efficient and cost-effective.
Solution Approach 2:
The laminated structure is designed as an integrated unit that can be assembled as a single component rather than multiple separate thin sheets. This segmentation approach reduces the number of handling steps required during assembly, thereby reducing handling time and operational costs.
3Ease of operation
If the anode current collector is cut multiple times during assembly, then the cell can be assembled, but costly damage may be applied to the thin sheets
Solution Approach 1:
The anode current collector is merged with separator layers to form a laminated structure that requires minimal cutting during assembly. This reduces the number of times the thin anode current collector must be cut, thereby maintaining its integrity and preventing costly damage while still allowing assembly operations to proceed.
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
This approach reduces the handling time and risk of damage to the anode current collector, enhances the assembly efficiency of anode-free cells, and extends the life of the cells by minimizing copper wrinkling and ensuring proper stacking.
Implementation Method 1
an anode current collector laminated in between the pair of separators to form a continuous laminated separator-current collector-separator layer
Data Source
AI summary
An anode-free cell including a housing and a plurality of cathode layers each cathode layer includes a cathode current collector disposed between two cathode active material layers. The anode-free cell also includes a pair of separators, and an anode current collector laminated in between the pair of separators to form a continuous laminated separator-current collector-separator layer. The continuous laminated separator-current collector-separator layer is positioned in between adjacent cathode layers of the plurality of cathode layers in a continuous stacking fold.