Battery Cell Manufacturing Device Gravity-Assisted Stacking
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Solution Overview
Problem
Current battery cell manufacturing processes are complex and costly, particularly for prismatic and pouch-shaped batteries, due to issues with stress concentration and short circuits in stack type electrode assemblies, and require significant space and equipment investment for stack/folding type electrode assemblies.
Innovation Solution
A battery cell manufacturing device that stacks unit cells with a separator in between, using a hopper-type unit cell stacking unit to facilitate gravity-assisted stacking, followed by wrapping with a separation film and thermal shrinking to improve processability and quality, while minimizing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If stack type electrode assembly is used, then prismatic structure is achieved, but manufacturing process becomes complicated and short circuits may occur due to electrode pushing under external impact
Solution Approach 1:
The electrode assembly is segmented into multiple independent pouch-shaped cells that are stacked together. Each pouch cell contains folded electrode plates with separators, creating discrete units that are less prone to short circuits while maintaining the overall prismatic shape of the battery pack.
Solution Approach 2:
The invention combines elements of both jelly-roll and stack type assemblies by using folded electrode plates within pouch cells, creating a composite structure that leverages the advantages of both types while mitigating their respective disadvantages.
2Device complexity
If stack/folding type electrode assembly is used, then manufacturing complexity is reduced, but significant space and equipment investment are required
Solution Approach 1:
The manufacturing process is segmented into independent steps for each pouch cell, allowing for compact, modular equipment layouts. Unit cells are assembled, folded, and sealed in separate stations that can be arranged in a space-efficient manner, reducing the overall manufacturing footprint.
3Productivity
If unit cells are stacked with physical pushing, then stacking is achieved, but stress concentrates on battery causing electrode detachment and deformation
Solution Approach 1:
A separator film is introduced as an intermediary element between stacked unit cells. This film distributes the stacking force uniformly across the electrode surfaces, preventing stress concentration and electrode detachment while maintaining effective stacking.
Solution Approach 2:
The separator film acts as a flexible intermediary layer that conforms to the electrode surfaces, distributing mechanical stress evenly during stacking operations and preventing deformation and detachment of electrode materials.
4Reliability
If separator film is wrapped and thermally shrunk, then unit cell stack is protected, but manufacturing process time increases
Solution Approach 1:
The separator film undergoes a thermal phase transition during shrinking, rapidly changing from a relaxed state to a tightly conforming state around the unit cell stack. This rapid phase change provides efficient protection without requiring prolonged processing time.
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 simplifies the manufacturing process, enhances battery cell quality and capacity, and reduces costs by allowing for efficient stacking and protection of unit cells without physical pushing, thereby improving the integration and reliability of battery cells.
Implementation Method 1
a heating unit to thermally shrink the separation film wrapping the outside of the unit cell stack
Implementation Method 2
a hopper-type unit cell stacking unit to facilitate gravity-assisted stacking
Data Source
Figure 1~2
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AI summary
Disclosed herein is a battery cell manufacturing device configured to manufacture a battery cell including two or more unit cells. The battery cell manufacturing device includes a unit cell stacking unit into which unit cells are introduced from above and in which the unit cells are sequentially stacked, a wrapping unit to wrap an outside of the unit cell stack discharged from the unit cell stacking unit with a separation film, and a heating unit to thermally shrink the separation film wrapping the outside of the unit cell stack.