Battery Pouch Foil Forming With Integrated Cell Stack Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing production methods for electrolyte pouch battery cells are inefficient due to serial process steps, high investment costs, and complex material handling, leading to long production times and increased costs.
Innovation Solution
A method and device utilizing two molding devices to reshape metal composite foils into pouch halves, allowing for simultaneous or sequential processing without removing the foils, with steps including reshaping, inserting a cell stack, and connecting the pouch halves to form a battery cell, reducing handling and enabling high cycle rates through positive or negative pressure and electromagnetic reshaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual process steps are carried out serially at different workstations, then each process step can be performed with dedicated equipment, but production time increases and investment costs rise
Solution Approach 1:
The patent combines multiple individual process steps (reshaping first pouch foil, reshaping second pouch foil, inserting cell stack, and connecting pouch halves) into a single integrated molding device. The first and second molding devices perform multiple operations simultaneously on their respective pouch foils, eliminating the need for serial processing at separate workstations and significantly reducing production time.
Solution Approach 2:
The integrated molding device enables continuous processing where pouch foils remain in the molding devices throughout the entire production sequence without removal or intermediate storage. The simultaneous reshaping and assembly operations maintain continuous useful action, preventing idle time between process steps that would occur in serial processing.
2Ease of manufacture
If multiple individual systems are used for production, then each system can be optimized for its specific function, but investment costs and space requirements increase
Solution Approach 1:
The molding devices are designed as multi-functional units that perform reshaping, holding, and assembly operations within a single system. Each molding device can reshape pouch foils and hold them during subsequent operations, eliminating the need for separate dedicated equipment for each process step while maintaining optimized functionality for all operations.
Solution Approach 2:
Multiple individual production systems are merged into a single integrated molding device that handles all production steps. This consolidation reduces the total number of systems from multiple separate workstations to one unified device, thereby reducing investment costs and space requirements while maintaining all necessary production functions.
3Ease of operation
If pouch foils are removed and handled between process steps, then material can be inspected and repositioned, but handling complexity and springback effects increase
Solution Approach 1:
The pouch foils are reshaped and positioned in the molding devices before subsequent operations begin. The molding devices maintain the pouch foils in their formed positions throughout the production sequence, preventing springback effects that would occur if the foils were removed and repositioned. This preliminary positioning action ensures manufacturing precision is maintained throughout the process.
Solution Approach 2:
The pouch foils remain continuously held and positioned in the molding devices without removal or intermediate handling. This continuous positioning eliminates the springback effects and handling complexity that would arise from removing and repositioning the foils between steps, while still allowing inspection and verification of the formed pouch structure.
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 significantly reduces production costs and time by minimizing handling and springback effects, improving product quality and accuracy, and allowing for efficient production of battery cells with reduced installation space requirements.
Implementation Method 1
reshaping by means of an atmospheric positive pressure
Implementation Method 2
reshaping by means of an atmospheric negative pressure
Implementation Method 3
reshaping by means of at least one electromagnetic pulse EMP
Data Source
AI summary
A method for producing a battery cell includes at least the following steps: a) reshaping a first pouch foil into a first pouch half by means of a first molding device with a first recess; b) reshaping a second pouch foil into a second pouch foil by means of a second molding device with a second recess; c) inserting a cell stack into the first molding device and the first pouch half located therein; d) bringing together the first molding device and the second molding device with the second pouch half located therein; and e) at least partially connecting the first and second pouch halves to form a battery cell.