Battery Separator Winding and Cutting Stability
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Solution Overview
Problem
The existing methods for manufacturing battery wound electrode assemblies face challenges in productivity due to instability in cutting and handling of separators during the winding process.
Innovation Solution
A method involving steps to wind and cut separators on a winding core, where the core is moved to different positions for stable cutting and re-winding, utilizing suction attachment and a presser roller for precise handling, and employing a wavy blade for clean cuts, improves the stability and productivity of the wound electrode assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separators are cut during the winding process using conventional methods, then the winding can proceed, but the cutting stability is poor leading to inconsistent cut quality and reduced productivity
Solution Approach 1:
The winding and cutting process is divided into distinct phases: winding phase where separators are wound onto the core, then cutting phase where the wound separators are cut. This segmentation allows each operation to be optimized independently, ensuring stable cutting while maintaining productivity.
Solution Approach 2:
The separators are pre-wound onto the winding core to form a compact, stable bundle before cutting. This preliminary winding action creates a stable workpiece geometry that enables consistent cutting quality, eliminating the instability that would occur if cutting were attempted on loose or partially wound separators.
2Productivity
If multiple winding cores are used to improve productivity, then more separators can be processed simultaneously, but the system complexity increases
Solution Approach 1:
Each winding core is designed to perform multiple functions: it serves as a winding surface for separators, a holding structure during the winding process, and a support for the cutting operation. This multi-functionality allows a single core to handle the entire winding and cutting sequence, and when multiple cores are used, they can operate in parallel to increase throughput without proportionally increasing system complexity.
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 method enhances the stability of the cut ends, ensures a consistent shape and thickness of the wound electrode assembly, thereby increasing production yield and productivity in battery manufacturing.
Implementation Method 1
when the first separator and the second separator are cut, the first separator may be suction-attached to the other winding core
Data Source
AI summary
A method of manufacturing a battery includes the step of: (A) winding a first separator, a second separator, a positive electrode plate, and a negative electrode plate onto a winding core disposed at a first position; (B) moving the winding core away from the first position and disposing another winding core at the first position; (C) cutting the first separator and the second separator wound on the winding core moved away from the first position, at a groove provided in an outer circumferential surface of the other winding core along the axial direction of the other winding core, with the first separator and the second separator being retained on the outer circumferential surface of the other winding core disposed at the first position; and (D) winding the first separator and the second separator onto the winding core moved away from the first position up to a cut edge portion.