Battery Cell Stack Assembly With Inline Terminal Cell Formation
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Solution Overview
Problem
Existing methods for producing battery cell stacks face challenges in large-scale industrial production regarding process time, effort, and process control, particularly in forming terminal cells with varying electrode sequences like SAS or SKS, which require additional handling and increase cycle times.
Innovation Solution
A method and device for producing battery cell stacks by aligning and joining electrode strands to form a composite strand, then separating monocells, and stacking them to create a battery cell stack with a repeating layer structure, allowing for inline production of terminal cells with omitted electrodes to achieve desired sequences like SAS or SKS.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If terminal cells with varying electrode sequences (SAS or SKS) are produced using existing methods, then the desired electrode sequences are achieved, but additional handling steps are required which increase process time and effort
Solution Approach 1:
The electrode strands are segmented into individual electrode sections that can be independently configured. By dividing the continuous electrode strand into discrete segments, the system can selectively omit electrodes at specific positions to create terminal cells with different sequences (SAS or SKS) without affecting the overall production flow, thereby eliminating additional handling steps.
Solution Approach 2:
The electrode strands are prepared in advance with predetermined electrode patterns during the strand formation process. By pre-configuring the electrode strands with the correct electrode sequences before stacking, the system eliminates the need for post-processing handling to create terminal cells with varying sequences, reducing process time and effort.
2Adaptability or versatility
If terminal cells with varying electrode sequences are produced using existing methods, then the desired electrode sequences are achieved, but additional handling steps are required which increase logistical effort
Solution Approach 1:
The electrode strands are divided into manageable segments with predetermined electrode configurations. This segmentation allows terminal cells with different sequences to be created directly during strand formation, eliminating the need for complex logistical coordination of separate electrode components and reducing overall operational complexity.
Solution Approach 2:
The electrode strand manufacturing system is designed to produce multiple types of electrode sequences (both standard and terminal cells with SAS or SKS sequences) using the same continuous process. This multi-functionality eliminates the need for separate production lines or additional handling procedures for different cell types, simplifying logistics and operation.
3Productivity
If a continuous process is used for producing battery cell stacks, then productivity is improved, but process control becomes more challenging
Solution Approach 1:
The electrode strands are pre-configured with predetermined electrode patterns and sequences during the strand formation process. By preparing the electrode strands in advance with the correct configurations, the continuous stacking process becomes simpler to control, as the variability is already determined before the high-speed stacking operation begins.
Solution Approach 2:
The system incorporates monitoring and control mechanisms that track the electrode strand configuration and stacking progress in real-time. By implementing feedback control, the system can maintain precise control over the continuous process, ensuring correct terminal cell formation while sustaining high productivity through uninterrupted operation.
Data Source
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AI summary
To manufacture battery cell stacks (22) in large-scale industrial production with very fast cycle times and low effort, such that both ends of the battery cell stack (22) terminate with the same type of electrode (A or K) and a separator (S), methods and devices for manufacturing battery cell stacks (22) are proposed. In these methods, a first and second electrode strand (32.1, 32.2) with separator track (34.1, 34.2) and first and second electrodes (36.1, 36.2) arranged at a distance from it are joined to form a composite strand (88), from which monocells (86) are separated. To form end cells (100), a second electrode (36.2) is omitted at certain points during the manufacture of the second electrode strand (32.2), so that a section of the respective separator track (34.2) is created without the corresponding second electrode.In the composite strand (88), a terminal cell region is formed in which a first electrode (36.1) is inserted between separator track segments. During the singulation of the cells (86, 100) from the composite strand (88), this electrode is separated into a terminal cell (100). Subsequent stacking can then begin or end with a terminal cell (100).