Electrode Assembly Manufacturing via Unit Structure Stacking
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Solution Overview
Problem
Existing methods for manufacturing electrode assemblies, such as stack and folding types, face challenges in achieving accurate alignment of electrodes, maintaining contact uniformity, and efficiently discharging gas between layers, leading to reduced productivity and service life due to temperature gradients and misalignment issues.
Innovation Solution
A method involving the formation of a unit structure by sequentially stacking electrodes and separators, followed by repeated layering and pressing to discharge interposed gas, utilizing a laminating process with controlled pressure and temperature to improve alignment and contact uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If stack and folding type electrode assemblies are manufactured by sequentially winding full cells on a separator sheet, then the electrode assembly can be formed with a compact structure, but temperature gradient is formed between central and outermost full cells leading to decreased service life
Solution Approach 1:
The electrode assembly is divided into multiple independent battery cells (first battery cell, second battery cell, third battery cell) that are stacked separately rather than wound continuously. This segmentation allows each cell to have uniform thermal characteristics and prevents the temperature gradient issue in large wound assemblies.
Solution Approach 2:
The manufacturing approach transitions from a planar winding structure to a three-dimensional stacked configuration. Multiple thin battery cells are stacked vertically to achieve compactness while maintaining uniform thermal distribution, avoiding the radial temperature gradient inherent in wound structures.
2Ease of manufacture
If two lamination apparatuses and a separate folding apparatus are employed to form stack and folding type electrode assemblies, then the assembly can be manufactured, but the process complexity increases and productivity is limited
Solution Approach 1:
The lamination and folding operations are merged into a single integrated lamination apparatus. The apparatus can perform both functions sequentially without requiring transfer between different machines, thereby simplifying the manufacturing process and improving productivity.
Solution Approach 2:
The lamination apparatus is designed with multi-functionality, capable of performing both lamination and folding operations. This universal device eliminates the need for separate specialized equipment, reducing process complexity and enhancing manufacturing efficiency.
3Manufacturing precision
If electrodes and separators are stacked one by one in stacked type electrode assemblies, then the assembly can be formed, but the working time increases significantly decreasing productivity
Solution Approach 1:
Multiple battery cells are prepared and pre-assembled before the final stacking operation. This preliminary preparation allows for more efficient final assembly, reducing the overall working time while maintaining alignment accuracy through pre-positioning of components.
Solution Approach 2:
The lamination apparatus performs continuous stacking operations without interruption, maintaining steady production flow. The integrated design allows seamless transition between lamination and folding, eliminating idle time and maximizing productivity while ensuring consistent alignment.
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 method enables economically efficient manufacturing with improved electrode assembly alignment, contact uniformity, and structural stability, enhancing the performance and service life of the electrode assembly.
Implementation Method 1
discharging gas interposed between the layers by pressing the electrode assembly
Implementation Method 2
utilizing a laminating process with controlled pressure and temperature to improve alignment and contact uniformity
Data Source
Figure 1
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AI summary
Provided is a method of manufacturing an electrode assembly which is different from a stack folding method and a stack method. The method includes forming a unit structure, which comprises a stacked structure formed by sequentially stacking a first electrode, a first separator, a second electrode, and a second separator, or a structure formed by repeatedly forming the stacked structure a plurality of times (operation S10), forming the electrode assembly by repeatedly stacking the unit structure into a plurality of layers (operation S20), and discharging gas interposed between the layers by pressing the electrode assembly (operation S30).