Battery Cell Electrode Stacking With Continuous Separator Unwinding
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Solution Overview
Problem
Existing manufacturing processes for rechargeable electric vehicle batteries, particularly pouch-type lithium-ion electrochemical cells, face challenges in achieving high productivity and reliability while ensuring safety, primarily due to complex and non-optimized stacking operations of electrodes.
Innovation Solution
A manufacturing process involving a series of optimized operations using a mobile stacking table and grippers to stack electrodes separated by a separator film, including vertical rectilinear movements and continuous unwinding, reduces the number of operations and optimizes tool movements to enhance production rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional electrode stacking operations are performed with multiple separate unwinding and placement steps, then electrode assembly can be completed, but the number of operations increases and production rate decreases
Solution Approach 1:
The patent combines multiple separate unwinding and electrode placement operations into a single integrated stacking operation. The separator film is unwound once and multiple electrodes are placed sequentially on it during one continuous process, eliminating the need for repeated unwinding and placement steps. This merging of operations directly increases production rate while reducing operational complexity.
Solution Approach 2:
The separator film is prepared and positioned in advance before the electrode stacking begins. By having the separator film ready and unwound prior to the stacking operation, the process eliminates delays that would occur if the separator film needed to be unwound and positioned for each individual electrode placement. This preliminary preparation enables faster, more continuous production.
2Productivity
If tools move at high speeds to increase production, then productivity improves, but precision and reliability of electrode stacking may deteriorate
Solution Approach 1:
The stacking process is divided into distinct phases: separator film unwinding, electrode placement, and stacking table movement. Each phase is optimized independently, allowing high-speed operation during unwinding and placement while maintaining precision during electrode alignment and stacking. This segmentation enables both high productivity and manufacturing precision to be achieved simultaneously.
Solution Approach 2:
The stacking table serves as an intermediary platform that receives electrodes and separator film, positions them precisely, and then transfers the assembled stack. This intermediary device decouples the high-speed unwinding/placement operations from the precision alignment requirements, allowing tools to move quickly while the stacking table ensures accurate electrode positioning and alignment.
3Productivity
If the stacking table moves along complex trajectories to accommodate all operations, then all electrodes can be stacked, but the number of movements increases and production rate decreases
Solution Approach 1:
Instead of moving the stacking table back and forth to accommodate separator film unwinding and electrode placement, the invention inverts the approach by moving the separator film and electrodes relative to the stacking table. The stacking table moves in a single direction (vertically downwards) while the separator film is unwound and electrodes are placed onto it, eliminating complex reciprocating movements and improving production rate.
Data Source
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AI summary
The invention relates to a method (12) for manufacturing a cell for a secondary battery, the method comprising: • - a first operation (O1) of moving a stacking table, wherein the movement is carried out in a first direction of movement; • - a second operation (O2) of unrolling a separator film onto the stacking table, wherein the separator film comprises a first electrode previously positioned thereon; • - a third operation (03) of moving the stacking table in a second direction of movement, opposite the first direction of movement; • - a fourth operation (04) of depositing a second electrode onto the separator film, wherein the second electrode is of opposite polarity to the first electrode; • - a fifth operation (05) of moving the stacking table in the first direction of movement.