Electrode Assembly Stacking Method for Secondary Battery Manufacturing
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Solution Overview
Problem
The manufacturing of stack/folding type secondary battery electrode assemblies is complex and prone to misalignment, with the wetting properties of the electrodes being compromised due to repeated folding of the separator, leading to increased production costs and reduced commercial value.
Innovation Solution
An electrode assembly is created using a stacking method where a bottom separator is wound around a radial unit, with a structure of alternately stacked electrodes and separators, and an outer separator that is longer than the cell stack part, simplifying the manufacturing process and improving wetting properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a stacking method is used to manufacture electrode assembly, then manufacturing complexity is reduced, but alignment precision of electrode units deteriorates
Solution Approach 1:
The electrode assembly is divided into multiple electrode units, each consisting of a first electrode, second electrode, and separator. This segmentation allows each unit to be manufactured and assembled independently, reducing overall manufacturing complexity while maintaining alignment precision through modular construction.
Solution Approach 2:
A first auxiliary unit and second auxiliary unit are introduced as intermediary components to facilitate precise alignment during assembly. These auxiliary units act as positioning guides that ensure accurate alignment of electrode units while simplifying the assembly process through standardized interfaces.
2Shape
If separator is wound multiple times by folding, then electrode assembly structure is formed, but wetting properties of electrode assembly deteriorate
Solution Approach 1:
Instead of folding the separator multiple times to form the electrode assembly structure, the invention inverts the approach by using a single separator that extends continuously through the assembly. The separator is positioned to contact both the first and second electrodes along their length, eliminating repeated folding and preserving wetting properties while still achieving the required structural formation.
3Ease of manufacture
If stack/folding type structure is used, then electrode assembly is manufactured, but alignment of full cells or hi-cells becomes difficult
Solution Approach 1:
The electrode assembly is segmented into multiple electrode units with standardized dimensions and configurations. Each unit contains a first electrode, second electrode, and separator arranged in a consistent pattern, allowing for precise alignment through repetitive modular assembly rather than complex folding operations.
Solution Approach 2:
Auxiliary units are introduced as intermediary positioning elements that guide the alignment of electrode units during assembly. These auxiliary components provide reference surfaces and positioning features that ensure precise alignment of full cells or hi-cells while simplifying the manufacturing process through standardized assembly procedures.
Data Source
AI summary
An electrode assembly includes a cell stack part having (a) a structure in which one kind of radical unit is repeatedly disposed, or (b) a structure in which at least two kinds of radical units are disposed in a predetermined order, the one kind or the at least two kinds of radical units having same number of electrodes and separators alternately disposed. The one kind of radical unit has four-layered structure in which first electrode, first separator, second electrode and second separator are sequentially stacked or repeating structure of the four-layered structure. Each of the at least two kinds of radical units are stacked by ones to form the four-layered structure or the repeating structure. An outer separator that is a separator among separators of a radical unit positioned at the outermost part of the cell stack part is extended from a side of the cell stack part.