Laminated Battery Cross-Stacking Segmentation Method
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Solution Overview
Problem
The existing methods for manufacturing laminated secondary batteries face challenges such as complex manufacturing processes, high equipment costs, and increased defective rates due to the difficulty in arranging and winding unit cells, leading to issues like local stress and short circuits during charge/discharge processes.
Innovation Solution
A method involving the cross-stacking of unit cells and electrode cells using a heat fusion process, where each unit cell is composed of a separation membrane, a cathode cell, and an anode cell, with electrodes of the same polarity laminated sequentially and wrapped with an outer film, simplifying the process and reducing reworking and initial investment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a stacked electrode assembly structure is used to obtain a_prismatic shape, then the battery shape is improved, but the manufacturing process becomes cumbersome and the electrode is pushed when impact is applied causing short circuit
Solution Approach 1:
The electrode assembly is divided into multiple unit cells (each containing anode, cathode, and separator) that are individually formed and then assembled together. This segmentation allows each unit cell to be manufactured independently with simpler processes while maintaining the overall_prismatic shape of the battery pack.
Solution Approach 2:
Multiple unit cells are nested within a common outer packaging structure that provides mechanical support and protection. The unit cells are arranged in a compact configuration inside the outer pack, allowing the_prismatic shape to be achieved through the outer packaging rather than the electrode assembly itself, thereby simplifying the manufacturing process.
2Productivity
If unit cells are arranged in a long sheet-like separation membrane one by one, then the electrode assembly can be formed, but the processing becomes very complicated and equipment investment cost increases
Solution Approach 1:
Instead of arranging unit cells one by one in a long sheet configuration, the invention segments the assembly process into forming multiple complete unit cells independently, then assembling them in a compact arrangement. This eliminates the need for complex long-sheet handling equipment and reduces processing complexity while maintaining productivity.
Solution Approach 2:
The unit cells are arranged in a three-dimensional compact configuration rather than being linearly arranged in a single dimension. This multi-dimensional arrangement reduces the overall length of the assembly process and eliminates the need for long sheet-like separation membranes, thereby simplifying equipment requirements.
3Quantity of substance
If more unit cells are arranged in a line, then the battery capacity increases, but the unit cells become difficult to wind and the defective rate increases
Solution Approach 1:
The battery is divided into multiple independent unit cells, each with a manageable number of electrodes. This segmentation allows each unit cell to be formed and assembled without the complexity of winding many cells in a line, thereby reducing the defective rate while achieving the desired total capacity through the combination of multiple unit cells.
Solution Approach 2:
Multiple unit cells are nested within a common outer packaging structure that provides mechanical support and protection. This nested arrangement allows unit cells to be stacked or arranged in a compact three-dimensional configuration rather than being linearly arranged, making assembly easier and reducing the defective rate while increasing battery capacity.
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, reduces defective products, and minimizes initial equipment costs by allowing for easier lamination and integration of unit and electrode cells, enhancing the stability and efficiency of the battery assembly.
Implementation Method 1
one full cell manufactured by the heat fusion process is laminated
Data Source
AI summary
Provided is a method of manufacturing a laminated secondary battery in which in the battery cell laminate in which the electrode cells are laminated, one full cell manufactured by the heat fusion process is laminated, and each unit electrode cell is laminated between each of the full cells to form one electrode assembly, thereby simplifying a manufacturing process, minimizing reworking due to defective electrode cells and minimizing an initial investment cost. To this end, provided is a method of manufacturing a laminated secondary battery having a structure in which two or more unit cells (a), an electrode cell (b), and an electrode cell (c) are cross stacked, including: 1) preparing a unit full cell, wherein the unit cell (a) is composed of a separation membrane/a cathode cell/a separation membrane/a anode cell/a separation membrane; 2) preparing an anode unit cell by the electrode cell (b) and a cathode unit cell by the electrode cell (c); and 3) sequentially laminating the unit cell (a), the electrode cell (b), the flipped-over unit cell (a′), and the electrode cell (c), wherein the laminated uppermost electrode has a structure in which electrodes having the same polarity as the lowermost polarity of the unit cell (a) are laminated, and wherein the laminate completed with the lamination is wrapped with the outer film, and the film end portion is fixed by the tape or the heat fusion.