Battery Electrode Assembly Zigzag Folding and Laser Bonding
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Solution Overview
Problem
The existing manufacturing process of electrode assemblies for batteries faces challenges with electrode misalignment, leading to potential battery capacity degradation and fire risks due to inner short-circuits, and requires costly equipment investments for maintaining alignment during transport.
Innovation Solution
A system comprising a folding device to laminate electrodes onto a separator in zigzags, with a bonding device for temporary laser bonding of electrode tabs during folding, and a holding device to maintain alignment, enhancing manufacturing speed and preventing misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrodes are alternately inserted into folded separator and pressed using transport pallets, then alignment during transfer is maintained, but manufacturing speed is reduced and equipment cost increases
Solution Approach 1:
The separator is pre-folded into a Z-shape configuration before electrode insertion, creating built-in alignment guides that maintain electrode positioning throughout the manufacturing process, eliminating the need for transport pallets and pressing structures
Solution Approach 2:
The patent removes the transport pallet and pressing structure from the manufacturing system, replacing them with a Z-shaped separator that inherently maintains alignment without requiring external support devices
2Manufacturing precision
If transport pallets with pressing structure are used, then electrode alignment is maintained, but equipment investment cost increases
Solution Approach 1:
The patent eliminates the need for expensive transport pallets and pressing structures by using the separator itself as the alignment mechanism through its Z-shaped configuration
Solution Approach 2:
The Z-shaped separator acts as a disposable alignment guide that is consumed during the manufacturing process, replacing expensive reusable transport pallets and pressing equipment
3Manufacturing precision
If electrodes are pressed during transfer, then misalignment is prevented, but manufacturing time increases
Solution Approach 1:
The separator is pre-folded into a Z-shape that creates built-in alignment guides, establishing electrode positioning before the manufacturing process begins, so no time is lost during transfer operations
Solution Approach 2:
The Z-shaped separator maintains electrode alignment continuously throughout the entire manufacturing process without interruption, eliminating the need to stop and press electrodes during transfer operations
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 system achieves high-speed manufacturing while ensuring precise electrode alignment, reducing the risk of battery degradation and fire hazards, and minimizing equipment costs by maintaining alignment during transport.
Implementation Method 1
the bonding device may be configured to bond the at least two electrodes by emitting a laser beam through one or more holes of the pair of grip units
Data Source
AI summary
Described herein is a system and/or method for manufacturing an electrode assembly for batteries. The system for manufacturing the electrode assembly may comprise a folding device configured to fold a laminated body, such that a plurality of electrodes may be disposed on a separator, into the electrode assembly, and a bonding device may be configured to temporarily bond electrode tabs of electrodes stacked on each other during the folding of the laminated body by the folding device.