Method for producing an electric battery with separator material on a current collector base
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Solution Overview
Problem
Current battery manufacturing processes are inefficient, requiring multiple tools and devices, leading to high production costs and extended production times.
Innovation Solution
A method involving the use of a current collector foil to support separators, which can be unrolled and placed intermittently with a lubrication layer, allowing for the creation of a separator-electrolyte-current collector unit, enabling a roll-to-roll process that reduces friction and physical stress, and facilitates faster manufacturing and cost reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional battery manufacturing processes are used with multiple tools and devices, then manufacturing precision can be maintained, but production time increases and production cost increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integrated process. The separator is placed directly onto the current collector foil in a continuous roll-to-roll manner, merging what would traditionally require separate handling, alignment, and assembly steps into one continuous operation. This reduces the number of tools and devices needed while maintaining manufacturing precision through the integrated process design.
Solution Approach 2:
The separator is pre-placed onto the current collector foil during the manufacturing process rather than being added later. This preliminary action allows subsequent electrode coating and assembly steps to proceed more efficiently, reducing overall production time. The separator-current collector assembly is prepared in advance as a integrated unit, eliminating the need for separate handling and alignment operations during final assembly.
2Productivity
If a current collector foil is used to support the separator instead of a polymer foil base, then production time is reduced and production cost is lowered, but manufacturing sensitivity increases
Solution Approach 1:
The patent introduces a lubrication layer as an intermediary between the separator and the current collector foil. This lubrication layer serves as a mediator that reduces friction and prevents direct contact between the separator and the sensitive current collector, thereby reducing manufacturing sensitivity and the risk of damage during handling. The lubrication layer allows the separator to be processed on the current collector foil without compromising the ease of manufacture.
3Device complexity
If separators are placed as a coating or periodically on the current collector, then device complexity is reduced, but manufacturing precision may be compromised
Solution Approach 1:
The patent employs a periodic placement pattern for the separator on the current collector foil, creating a segmented structure where separator sections are distributed at regular intervals. This segmentation approach simplifies the manufacturing process by using repetitive patterns rather than continuous complex structures, while maintaining manufacturing precision through controlled periodic placement. The segmented design allows for easier alignment and quality control during the roll-to-roll manufacturing process.
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 minimizes production costs and time by simplifying the manufacturing process, allowing for the efficient production of battery cell components and enabling the creation of battery stacks for electric or hybrid vehicles.
Implementation Method 1
a lubrication layer can be placed between the separator/sepolyte and the current collector. This lubrication layer is soft and allows a sliding and reduces friction between the separator/sepolyte and current collector during manufacturing and charging/discharging of the battery cell.
Data Source
AI summary
The present invention provides a method for manufacturing a battery cell component including providing a current collector foil and placing separators onto the current collector foil at spaced intervals. A battery cell component, battery and electric or hybrid vehicle is also provided.