Electrode Alignment on Separator Sheets Before Battery Lamination
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Solution Overview
Problem
Existing electrode assembly manufacturing processes struggle to maintain uniform intervals between unit electrodes and align positive and negative electrodes accurately, leading to misalignment and decreased battery performance.
Innovation Solution
An electrode manufacturing apparatus with sensor units to sense electrode positions and alignment units to adjust transfer speeds, ensuring uniform intervals and alignment before lamination, using correction rolls and vision inspection to correct misalignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If unit electrodes are cut from electrode sheets and stacked for lamination, then electrode assembly is manufactured, but the interval between unit electrodes becomes non-uniform causing misalignment between positive and negative electrodes
Solution Approach 1:
The patent applies preliminary action by performing alignment adjustment of unit electrodes on the separator sheet before the lamination process. The alignment unit adjusts the position of unit electrodes while they are still on the separator sheet, allowing misalignment to be corrected in advance before electrodes are stacked and laminated, thereby ensuring precise alignment without requiring complex post-lamination adjustment systems
Solution Approach 2:
The separator sheet serves as an intermediary carrier that enables alignment adjustment. By providing a flat, stable surface during the alignment process, the separator sheet allows the alignment unit to precisely position unit electrodes before they are stacked for lamination, facilitating accurate alignment without direct manipulation of the electrodes themselves during the adjustment phase
2Reliability
If alignment is checked after lamination process, then defective electrodes can be sorted and excluded, but defective electrode incidence rate cannot be reduced
Solution Approach 1:
The patent performs alignment verification and adjustment before the lamination process rather than after. The alignment unit and sensor unit detect and correct misalignment of unit electrodes on the separator sheet prior to stacking and lamination, preventing defective assemblies from being created in the first place, thereby reducing the defective electrode incidence rate while maintaining high reliability
Solution Approach 2:
The patent implements a feedback mechanism where sensor units detect the position of unit electrodes on the separator sheet, and this information is fed back to the alignment unit which automatically adjusts electrode positions. This closed-loop control system ensures accurate alignment before lamination, preventing defects rather than merely detecting them after production
3Manufacturing precision
If sensor units and alignment units are added to adjust transfer speeds, then uniform intervals and alignment are achieved, but device complexity increases
Solution Approach 1:
The separator sheet serves multiple functions: it acts as a carrier for transporting unit electrodes, provides a flat surface for alignment adjustment, and serves as a base for stacking electrodes during lamination. This multi-functionality reduces the need for separate dedicated components, thereby achieving uniform intervals and precise alignment without proportionally increasing device complexity
Solution Approach 2:
The alignment unit adjusts the position of unit electrodes directly on the separator sheet using the separator sheet's own surface properties and structure. The system utilizes the existing separator sheet infrastructure to perform alignment functions, rather than requiring completely separate complex positioning mechanisms, thereby achieving precise control with moderate complexity increase
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
Ensures precise alignment and uniform intervals between electrodes, preventing defects and enhancing battery capacity and energy density by maintaining consistent electrode coupling.
Implementation Method 1
a first sensor unit configured to sense the position of the first unit electrode
Implementation Method 2
a first alignment unit configured to adjust transfer speeds of both ends of the first unit electrode parallel to a transfer direction thereof
Data Source
AI summary
Electrode and electrode assembly manufacturing apparatuses include an electrode transfer unit for transferring an electrode with coating layer on surface of the electrode, a cutter for cutting the electrode transferred by the electrode transfer unit to form a unit electrode, a separator transfer unit disposed at one surface of the electrode transfer unit and configured to transfer a separator, a sensor unit for sensing the position of the unit electrode and an alignment unit for adjusting transfer speeds of outer peripheries of the unit electrode parallel to a unit electrode transfer direction to adjust the interval between unit electrodes seated on a separator surface. Whether positive and negative electrodes are aligned before stacking and laminating electrodes having different polarities is determined. The positive and negative electrodes are then stacked, whereby the occurrence of a defective electrode due to misalignment between the positive and negative electrodes is preventable.