Continuous Bagged Electrode Bonding for High-Speed Battery Assembly

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Solution Overview

Problem

Existing battery manufacturing techniques face challenges in achieving high-speed production of laminated batteries due to difficulties in handling and accurately positioning thin-film separators between positive and negative electrodes, leading to inefficiencies and increased production time.

Innovation Solution

A bagged electrode manufacturing apparatus that conveys an electrode interposed between long separator materials, bonds them using a press-lock method without stopping the conveyance, and cuts the separators to form a bagged electrode, enabling efficient layering and higher productivity in battery production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separators are cut into sheet shape and positioned between electrodes, then battery structure is formed, but handling difficulty increases and positioning accuracy decreases

Engineering Contradiction:

Improvehandling easeVSAvoidpositioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The separator is not cut into individual sheets but remains as a continuous long strip that is bonded to multiple electrodes sequentially. This segmentation approach divides the manufacturing process into discrete bonding zones while maintaining the separator's continuity, making handling easier without sacrificing positioning accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator is prepared in advance as a long continuous strip with predetermined bonding zones marked or pre-positioned. This preliminary preparation allows the separator to be easily handled and positioned before the actual bonding process begins, improving both handling ease and positioning accuracy.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If pick-and-place method is used to layer bagged electrodes, then assembly is achieved, but manufacturing speed decreases

Engineering Contradiction:

Improvemanufacturing speedVSAvoidassembly complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The manufacturing process uses continuous conveyance of the electrode-separator assembly through the system without stopping. The bonding units operate continuously as the assembly moves along, eliminating the need for stop-and-go pick-and-place operations and significantly improving manufacturing speed.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Multiple bonding units are merged into a single continuous processing line where each unit performs bonding at different positions along the conveyance path. This combines multiple operations into one continuous flow process, reducing assembly complexity while maintaining high productivity.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If bonding is performed without stopping conveyance, then manufacturing efficiency increases, but bonding precision may decrease

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidbonding precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The bonding units are designed to operate dynamically during continuous conveyance, with each bonding unit positioned to apply precise bonding pressure at specific locations along the movement path. The system adapts the bonding process to the moving substrate, maintaining precision despite the continuous motion.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent replaces traditional stationary mechanical bonding systems with a moving conveyor-based system where bonding is achieved through controlled pressure application during motion. This substitution allows continuous operation while maintaining bonding precision through careful control of pressure, speed, and positioning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 apparatus allows for faster and more efficient manufacturing of laminated batteries by integrating the electrodes with separators, reducing production time and improving handling efficiency, and can be applied to larger battery sizes without additional steps.

Implementation Method 1

a press-lock bonding unit that bonds the pair of long separator materials outside the electrode without stopping conveyance of the electrode and the pair of long separator materials

Methodology Applied

Scientific EffectPress-lock method: Mechanical Force

Data Source

PatentUS11923492B2Apparatus for manufacturing bagged electrode, accumulating apparatus, and method for manufacturing bagged electrode

Publication Date: 2024.03.05 KK TOSHIBA

AI summary

An apparatus for manufacturing a bagged electrode includes a conveying unit, a first bonding unit, a second bonding unit, and a separating unit. The conveying unit conveys an electrode in a manner interposed between a pair of long separator materials unwound from a pair of rolls. The first bonding unit bonds the pair of long separator materials outside the electrode along a conveyance direction without stopping conveyance of the electrode and the pair of long separator materials. The second bonding unit bonds the pair of long separator materials outside the electrode along a direction intersecting the conveyance direction without stopping conveyance of the electrode and the pair of long separator materials. The separating unit cuts the pair of long separator materials along the direction intersecting the conveyance direction to cut off the bagged electrode without stopping conveyance of the electrode and the pair of long separator materials.