Battery Core Forming via Orbital Winding and Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional cell manufacturing methods result in core deformation and reduced strength when transforming a cylindrical shape into an oblong shape, leading to potential deflection and decreased discharge capacity under high temperature conditions.
Innovation Solution
A method involving the use of a sheet inserted between winding shafts, which are then rotated to form a core with curved portions projecting in different directions, enhancing strength and stability without complex production steps, and incorporating adhesive or melt bonding of separators to maintain tension and enhance core strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a cylindrical core is pressed from both sides to transform it into an oblong shape, then the cell can be manufactured with a compact form factor, but the core strength is reduced and deformation occurs under pressing force
Solution Approach 1:
Instead of pressing a cylindrical core to deform it into an oblong shape, the invention inverts the approach by directly forming the core into an oblong shape with curved portions during the winding process. This avoids the pressing step that causes strength reduction while achieving the desired compact form factor.
Solution Approach 2:
The core is pre-formed with an oblong shape and curved portions during the winding process before the electrodes are wound around it. This preliminary shaping eliminates the need for subsequent pressing operations that would compromise core strength.
2Volume of moving object
If a cylindrical core is pressed into an oblong shape, then space utilization is improved, but deflection of electrodes occurs under high temperature conditions
Solution Approach 1:
The invention inverts the conventional approach by directly forming an oblong core with curved portions during winding, rather than pressing a cylindrical core afterward. This maintains structural integrity under high temperature, preventing electrode deflection while achieving compact space utilization.
3Strength
If complex production steps are added to manufacture high-strength cores, then core strength is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The invention merges the core shaping process with the electrode winding process into a single integrated operation. The oblong shape with curved portions is formed during winding itself, eliminating the need for separate pressing or shaping steps, thus maintaining high strength without increasing manufacturing complexity.
Solution Approach 2:
The winding process serves multiple functions simultaneously: it forms the core structure, creates the oblong shape with curved portions, and prepares the core for electrode assembly. This multi-functionality achieves high strength without adding complex dedicated shaping equipment or steps.
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 achieves high-strength cores that resist deformation and maintain discharge capacity, allowing for cost-effective and efficient cell production with improved performance under continuous high-temperature use.
Implementation Method 1
The sheet S is inserted between the two winding shafts 5, 5 and then fixed to the first winding shaft 5 at its end or a vicinity thereof, for example, and in this state, the pair of winding shafts 5, 5 are revolved by a predetermined angle to wind the sheet S
Implementation Method 2
the separators 23, 23 are overlapped at one ends thereof and joined by adhesive bonding or melt bonding to the sheet S
Implementation Method 3
the separators 23, 23 are overlapped at one ends thereof and joined by adhesive bonding or melt bonding to the sheet S
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Provided are a method for manufacturing a cell that does not require a deformation process by pressing to provide a cell that is inexpensive and has high strength, and a method and apparatus for manufacturing a core. The method for manufacturing a cell includes: a first step of manufacturing a core 20 using a core manufacturing apparatus, the apparatus including a pair of winding shafts 5, 5 that are disposed with a rotation center of the apparatus interposed therebetween, the pair of winding shafts 5, 5 orbitally moving about the rotation center; and a second step of fabricating a laminated electrode member 25 with a sheet-shaped positive electrode 21, a sheet-shaped negative electrode 22 and a pair of sheet-shaped separators 23, 23 interposed thereto to be arranged alternately with the electrodes; and winding the laminated electrode member 25 around a circumferential surface of the core 20, wherein the first step includes: inserting a sheet S having a higher strength than the separators between the winding shafts 5, 5; orbitally moving the pair of winding shafts 5, 5; and then, adhesively bonding or melt-bonding overlapped portions of the sheet S at the winding shafts 5, 5.