Battery Lamination via Insulating Mylar Base
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Solution Overview
Problem
The existing battery manufacturing process is prone to contamination from foreign matter and inefficiencies due to the transfer of cells wrapped with insulating film, which affects production quality and efficiency.
Innovation Solution
The method involves laminating a separator film onto an insulating Mylar, then wrapping the laminated cell with the same insulating Mylar, eliminating the need for cell transfer and reducing the risk of contamination and improving production efficiency by maintaining the relative positions of the cell and film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single cell is transferred to an insulating film for wrapping, then the cell can be properly insulated, but foreign matter may be mixed into the battery and production efficiency is reduced
Solution Approach 1:
The insulating film is prepared in advance on the laminating device before the cell is stacked. The pole pieces and separator films are laminated directly onto the pre-positioned insulating film, eliminating the need for subsequent transfer operations. This preliminary positioning of the insulating film ensures proper insulation while avoiding contamination risks from transfer processes.
Solution Approach 2:
The lamination process and insulating film wrapping are merged into a single integrated operation. The insulating film serves dual purposes: it provides insulation and acts as the base layer for lamination. By combining these functions, the patent eliminates separate transfer steps while maintaining insulation quality.
2Reliability
If a single cell is transferred to an insulating film for wrapping, then the cell can be properly insulated, but the transfer process introduces contamination risk
Solution Approach 1:
The insulating film is positioned and prepared on the laminating device before the cell components are stacked. This preliminary action allows the insulating film to be part of the fixed lamination structure, eliminating the need to transfer the cell to the film later, thus preventing foreign matter contamination during transfer.
Solution Approach 2:
The laminating device serves as an intermediary platform that integrates both the insulating film and the lamination process. By using this intermediary structure, the patent eliminates direct contact between the cell and external handling tools that could introduce contaminants.
3Ease of manufacture
If the insulating mylar is applied after cell formation, then the cell structure is complete, but additional processing steps are required
Solution Approach 1:
The insulating film application and cell lamination are merged into a single simultaneous process. The insulating film is positioned on the laminating device first, and then the pole pieces and separator films are laminated directly onto it in one continuous operation, eliminating separate steps for film application and cell assembly.
Solution Approach 2:
The insulating film is prepared and positioned in advance on the laminating device before the cell components are stacked. This preliminary preparation allows the insulating film to be integrated into the lamination process itself, reducing the number of subsequent processing steps required.
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 enhances manufacturing efficiency and prevents foreign matter from entering the battery, ensuring better quality and reduced production time by integrating the insulating Mylar directly into the cell formation process.
Implementation Method 1
Laminating on the insulating mylar to form a laminated cell
Data Source
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AI summary
The disclosure relates to the technical field of batteries, and provides a battery manufacturing method, a battery, a battery module, and a battery pack. The battery manufacturing method includes following steps. Providing an insulating mylar (10), laminating on the insulating mylar (10) to form a laminated cell (20) that includes a separator film (23) different from the insulating mylar (10), and wrapping the laminated cell (20) with the insulating mylar (10). By laminating on the insulating mylar (10) to form the laminated cell (20) and then wrapping the laminated cell (20) with the insulating mylar (10), a process of moving the laminated cell (20) to the insulating mylar (10) is omitted.