Battery Cell Stack Lamination Using Induction Heating

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Solution Overview

Problem

Existing methods for laminating battery cell stacks are time-critical due to heat transfer by conduction, requiring processing times of 45 to 60 seconds per stack, which limits production efficiency and quality.

Innovation Solution

A method and apparatus using induction heating to laminate battery cell components, allowing for precise alignment and adhesion between electrodes and separator layers, with direct heating via induction coils and controlled pressure, enabling lamination in less than 20 seconds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If heat press machines with conduction heating are used to laminate battery cell stacks, then the stacking direction alignment is maintained, but the processing time increases to 45-60 seconds per stack

Engineering Contradiction:

Improvealignment precisionVSAvoidprocessing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the mechanical conduction heating system with an induction heating system. Induction heating uses electromagnetic fields to directly heat the separator material, eliminating the need for thermal conduction through press plates. This substitution reduces processing time from 45-60 seconds to under 20 seconds while maintaining the alignment precision achieved through controlled pressing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the heating parameter from thermal conduction to electromagnetic induction. By using induction heating, the system achieves rapid heating of the separator material without requiring prolonged contact time under pressure, thus reducing the overall processing time while maintaining adequate alignment through the pressing phase.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If induction heating is used to heat the separator material, then the processing time is reduced to less than 20 seconds, but the heating uniformity across large stacks may be compromised

Engineering Contradiction:

Improveprocessing speedVSAvoidheating uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by using multiple induction heating zones or adjustable induction parameters tailored to different regions of the stack. This allows selective heating optimization across the stack surface, ensuring uniform heating even for large stacks while maintaining the rapid processing speed advantage of induction heating.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent incorporates feedback control in the induction heating system to monitor and adjust heating parameters in real-time. This ensures uniform temperature distribution across the separator material, preventing overheating in some regions while ensuring adequate heating in others, thus maintaining heating uniformity at high processing speeds.

Inventive Principle:

Principle #23Feedback

3Strength

If high pressure is applied during lamination to ensure adhesion, then the bonding strength increases, but the risk of damaging the porous structure of separator material increases

Engineering Contradiction:

Improveadhesive bond strengthVSAvoidstructural damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent uses periodic or pulsed pressure application combined with induction heating. The pressure is applied in controlled pulses during the heating process, allowing the separator material to achieve adequate bonding strength without sustained high pressure that could damage its porous structure. The rapid induction heating reduces the total time high pressure is needed.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent utilizes the phase transition or thermal softening of the separator material during induction heating to achieve adhesion. The rapid heating causes the separator material to become more pliable and adhesive, allowing bonding to occur at lower pressures than would be required at room temperature, thus preserving the porous structure while ensuring adequate bond strength.

Inventive Principle:

Principle #36Phase transitions

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

Achieves rapid and homogeneous heating of large stacks, maintaining the porous structure of separator materials, and ensuring precise alignment of electrodes, thereby improving production efficiency and quality.

Implementation Method 1

heating the at least one separator layer, in particular by induction, to form an adhesive bond

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 2

laminating involves heating the separator layers or separator materials so that they form an adhesive bond with the adjacent active material of the electrode

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS20260005282A1Method and device for laminating components of a battery cell

Publication Date: 2026.01.01 POWERCO SE

AI summary

A method for laminating components of a battery cell is provided. The components comprising at least one electrode of a first electrode type and a separator layer, which are arranged on top of one another along a stacking direction and form a stack. In addition, an apparatus for laminating components of a battery cell is disclosed.