Electrode Assembly Roll Pressing With Elastic Layers and Tab Sealing

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Solution Overview

Problem

Existing electrode assembly manufacturing processes result in damage to electrodes and separators due to height differences causing impacts and inability to seal electrode tabs, leading to shorts and poor sealing quality.

Innovation Solution

The use of elastic layers and deformation prevention rollers on manufacturing apparatus to uniformly press and combine electrodes and separators, preventing damage and improving sealing by maintaining an even pressing surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a roller made of metal material is used to press and combine electrodes and separator, then the pressing force is sufficient, but the stepped portion causes impact damage to electrodes and separators

Engineering Contradiction:

Improvepressing forceVSAvoidimpact damage

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

The roller surface material is changed from rigid metal to elastic material, fundamentally altering the mechanical properties of the pressing surface. This parameter change allows the roller to deform elastically under load, absorbing impact energy and preventing damage to the electrodes and separator while maintaining sufficient pressing force for combination.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The elastic material layer is applied beforehand on the roller surface to create a cushioning effect. This pre-established elastic layer absorbs the impact that would otherwise be transmitted to the electrodes and separator at the stepped portion, preventing damage before it occurs during the pressing operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Strength

If a metal roller is used for pressing, then the structural strength is sufficient, but sealing of electrode tab side surface is impossible

Engineering Contradiction:

Improveroller strengthVSAvoidsealing quality

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The surface material parameter of the roller is changed from metal to elastic material, which enables the roller to conform to the electrode tab side surface geometry. This allows the elastic roller to create effective sealing contact that rigid metal rollers cannot achieve, while the underlying metal structure maintains the required mechanical strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The elastic material layer acts as a flexible surface on the roller that can deform to match the contour of the electrode tab side surface. This flexibility enables the roller to create uniform sealing contact across the entire surface, solving the sealing impossibility issue with rigid metal rollers.

Inventive Principle:

Principle #30Flexible shells and thin films

3Force

If electrodes and separator are pressed with a rigid roller, then the combination force is adequate, but height difference causes stepped portion formation

Engineering Contradiction:

Improvecombination forceVSAvoidsurface uniformity

Core Design Contradiction:

ForceVSShape

Solution Approach 1:

The roller surface is transformed from rigid to elastic, changing its deformation characteristics under load. This parameter change allows the roller surface to conform to the uneven height profile of stacked electrodes and separator, eliminating stepped portions while maintaining adequate combination force through elastic deformation.

Inventive Principle:

Principle #35Parameter changes

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

Prevents impacts and damage to electrodes and separators, ensuring uniform pressing and enhanced sealing quality during the manufacturing process.

Implementation Method 1

a first elastic layer and a second elastic layer, provided along an outer circumferential surface of the first roller and comprising an elastic material

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

a first deformation prevention roller provided to be in contact with an outer circumferential surface of the first elastic layer to prevent the outer circumferential surface of the first elastic layer from being deformed

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12580216B2Apparatus for manufacturing electrode assembly, electrode assembly manufactured therethrough, and secondary battery

Publication Date: 2026.03.17 LG ENERGY SOLUTION LTD

AI summary

An apparatus for manufacturing an electrode assembly includes a first roller and a second roller, which press both sides of a stack, in which electrodes and a separator are alternately stacked, a first elastic layer provided along an outer circumferential surface of the first roller and comprising an elastic material, and a first deformation prevention roller provided to be in contact with an outer circumferential surface of the first elastic layer so as to prevent the outer circumferential surface of the first elastic layer from being deformed.