Battery Cell Electrode Stacking With Vacuum Alignment Control
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Solution Overview
Problem
Large secondary batteries experience sagging and curving phenomena during the transfer of negative, separator, and positive electrodes, leading to misalignment and reduced battery capacity.
Innovation Solution
An apparatus that stacks negative, separator, and positive electrodes by cutting them to preset lengths and using integrated unwinding, seating, cutting, and inversion portions with vacuum adsorption and servo-motor assisted rotation to maintain precise alignment and prevent sagging, while reducing the overall manufacturing apparatus size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electrodes are transferred in large secondary batteries, then battery capacity increases, but sagging and curving phenomena occur causing misalignment
Solution Approach 1:
The electrode transfer process is divided into multiple controlled stages: unwinding from roll, cutting to preset length, vacuum adsorption for stabilization, and inversion. Each stage is independently controlled to prevent sagging and curving while maintaining alignment precision for large-capacity batteries
Solution Approach 2:
The electrodes are cut to preset lengths before transfer and placed on vacuum adsorption surfaces in advance. This preliminary preparation stabilizes the electrode shapes before the actual stacking operation, preventing misalignment during the transfer process for large battery configurations
2Quantity of substance
If electrode transfer distance is increased for large batteries, then battery capacity increases, but curving phenomenon worsens
Solution Approach 1:
Electrodes are cut to precise lengths and stabilized on vacuum adsorption surfaces before transfer. This preliminary stabilization prevents curving from developing during long-distance transfer operations in large battery manufacturing
Solution Approach 2:
The vacuum adsorption table acts as an intermediary stabilization surface between the electrode source and final stacking position. This intermediary surface maintains electrode flatness and prevents curving during the transfer process for large battery configurations
3Manufacturing precision
If stacking precision is improved, then electrode alignment improves, but device complexity increases
Solution Approach 1:
The vacuum adsorption table serves multiple functions: it stabilizes electrodes during cutting, maintains alignment during transfer, and prevents curving during inversion. This multi-functional component achieves high stacking precision without proportionally increasing device complexity
Solution Approach 2:
The vacuum adsorption system automatically stabilizes and maintains electrode alignment without requiring additional complex positioning mechanisms. The system self-regulates to maintain precision through vacuum control, reducing the need for extra alignment devices
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 effectively suppresses sagging and curving phenomena, improves electrode alignment, and enhances battery capacity by optimizing the stacking process and reducing foreign material inflow through optimized disposition and position adjustment.
Implementation Method 1
a plurality of clampers disposed along a circumference of the table, and configured to operate in a direction toward or away from the table through a first linear module, to vertically operate through a second linear module mounted on the first linear module, and to clamp the negative electrode, the separator, and the positive electrode stacked on the upper surface of the table
Implementation Method 2
configured to operate in a direction toward or away from the table through a first linear module, to vertically operate through a second linear module mounted on the first linear module
Data Source
AI summary
An apparatus for manufacturing a battery cell by stacking a negative electrode, a separator, and a positive electrode includes, a loading unit of loading the negative electrode, separator, and positive electrode, a negative electrode stacking unit disposed adjacent to the loading unit, and configured to cut a negative electrode material unwound from a negative electrode roll to a preset length and stack the cut negative electrode material on the loading unit, a separator stacking unit disposed adjacent to the loading unit, and configured to cut a separator material unwound from a separator roll to a preset length and to stack the cut separator material on the loading unit, and a positive electrode stacking unit disposed adjacent to the stacking unit, and configured to cut a positive electrode material unwound from a positive electrode roll to a preset length and stack the cut positive electrode material on the loading unit.