Horizontal Electrode Assembly Loading for Current Collector Integrity

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Solution Overview

Problem

The conventional vertical insertion method for electrode assemblies in secondary batteries risks deformation or damage to related parts due to the increasing weight of the electrode assembly, particularly affecting current collectors and welded portions.

Innovation Solution

A horizontal insertion method and apparatus are employed, where the electrode assembly and case are mounted horizontally, using supports to prevent sagging and deformation by moving one of them relative to the other, ensuring a stable assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If vertical insertion method is used, then insertion process is simple, but deformation or damage occurs to current collectors and welded portions due to electrode assembly weight

Engineering Contradiction:

Improveinsertion process simplicityVSAvoidcurrent collector integrity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent inverts the conventional vertical insertion method by implementing horizontal insertion. The electrode assembly and case are positioned horizontally, and the assembly proceeds in a horizontal direction rather than vertical. This inversion eliminates the gravitational load on the current collector during insertion, preventing deformation and damage while maintaining process simplicity.

Inventive Principle:

Principle #13The other way round (Inversion)

2Quantity of substance

If electrode assembly weight increases, then battery capacity improves, but deformation risk to related parts increases

Engineering Contradiction:

Improvebattery capacityVSAvoiddeformation risk

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent changes the insertion orientation parameter from vertical to horizontal. This parameter change fundamentally alters the gravitational force direction relative to the current collector, eliminating the harmful deformation effect while allowing continued increase in electrode assembly weight for higher battery capacity.

Inventive Principle:

Principle #35Parameter changes

3Strength

If horizontal insertion is implemented, then deformation of current collectors is prevented, but device complexity increases due to support requirements

Engineering Contradiction:

Improvecurrent collector integrityVSAvoidsupport assembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent introduces support assemblies that act as counterbalancing elements during horizontal insertion. These supports prevent sagging of the electrode assembly by providing upward counterforce to gravity, thereby maintaining current collector integrity without requiring overly complex positioning mechanisms.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Data Source

PatentUS20250372689A1Apparatus and method for manufacturing secondary battery including horizontal insert unit of electrode assembly

Publication Date: 2025.12.04 SAMSUNG SDI CO LTD

AI summary

An apparatus and a method for manufacturing a secondary battery involve an electrode assembly being horizontally inserted into a case in a state in which the case and the electrode assembly are placed horizontally in order to prevent deformation of related parts such as a current collector due to the weight of the electrode assembly. The apparatus for manufacturing a secondary battery includes a horizontal insert unit in which a cap plate is assembled and which horizontally inserts a horizontally mounted electrode assembly into an opening of a horizontally mounted case.