Curved Electrode Assembly Manufacturing via Roll Lamination
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Solution Overview
Problem
Conventional methods for manufacturing curved secondary batteries face challenges in maintaining shape stability due to deformation caused by the expansion and contraction of active materials during charging and discharging, leading to potential short circuits and limited shape versatility.
Innovation Solution
A method involving a roll lamination process to produce unit cells with a uniform curvature radius, controlled through temperature, pressure, and rotational speed, and then stacking these cells using jigs with matching curvature to create a curved electrode assembly with a maximum curvature radius difference of less than 10%, ensuring high shape stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flat plate-shaped electrode assembly is pressed by a curved jig to fabricate a curved battery, then the battery can be adapted for various shapes and sizes, but the electrode assembly experiences deformation and warpage during repeated charge and discharge cycles
Solution Approach 1:
The electrode assembly is pre-formed with a curved shape matching the target battery configuration before assembly. This preliminary shaping ensures that the electrode structure is already adapted to the desired curvature, preventing deformation during subsequent charge-discharge cycles while maintaining shape stability
Solution Approach 2:
The invention changes the curvature radius parameter of the electrode assembly to match the target battery shape. By carefully selecting and controlling the curvature radius during manufacturing, the electrode assembly achieves both the desired shape adaptability and maintains structural stability during operation
2Volume of moving object
If the curvature radius is reduced to achieve more compact battery designs, then the battery size is reduced, but warpage increases and shape stability deteriorates
Solution Approach 1:
The electrode assembly is pre-formed with a curved shape matching the target battery configuration before assembly. This preliminary shaping ensures that the electrode structure is already adapted to the desired curvature, preventing deformation during subsequent charge-discharge cycles while maintaining shape stability
Solution Approach 2:
The invention changes the curvature radius parameter of the electrode assembly to match the target battery shape. By carefully selecting and controlling the curvature radius during manufacturing, the electrode assembly achieves both the desired shape adaptability and maintains structural stability during operation
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
The method effectively maintains the curved shape of the electrode assembly with low restoration to the original shape, enhancing shape stability and allowing for the fabrication of desired curvature radii without excessive deformation.
Implementation Method 1
the curved shape is achieved through thermal compression molding using a concave heater and a convex heater
Implementation Method 2
compressing the stack structure to prepare a unit cell
Implementation Method 3
a curved electrode assembly having a curve with a uniform curvature radius
Data Source
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AI summary
The present disclosure relates to a method for manufacturing an electrode assembly for an electrochemical device. More particularly, the present disclosure relates to a method for manufacturing a curved electrode assembly having a curve with a uniform curvature radius. According to the present disclosure, as the curved electrode assembly is manufactured by stacking a plurality of curved unit cells having a uniform curvature radius R, restoration to the original shape is low and shape stability is high as compared to an electrode assembly manufactured by bending a flat electrode assembly. In addition, as unit cells included in an electrode assembly are produced to have a curve by a roll lamination process under a uniform condition and they have the same curvature radius R or a small difference in curvature radius R, it is possible to easily manufacture an electrode assembly having a desired curvature radius R without excessive deformation of the unit cells.