Continuous Electrode Cell Stacking for Precise Battery Assembly
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Solution Overview
Problem
The manufacturing process of stack and folding type secondary battery electrode assemblies is prone to defects, waste loss, and inventory management challenges due to difficulties in accurately positioning and folding unit cells during the assembly process.
Innovation Solution
A continuous manufacturing system for secondary batteries that includes parallel positive and negative electrode cell manufacturing lines, a stacking part for alternating and aligning electrode cells, a welding part for connecting tabs, and a packaging part for sealing the electrodes in a pouch, allowing for real-time error correction and reduced waste through continuous processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If unit cells are manually positioned and folded during electrode assembly manufacturing, then flexibility in handling defects is improved, but manufacturing precision and productivity deteriorate due to positioning errors and process delays
Solution Approach 1:
The patent replaces manual mechanical positioning and folding operations with an automated stacking device that uses mechanical conveyors, positioning mechanisms, and folding arms. This substitution eliminates human positioning errors while maintaining operational flexibility through programmable control, directly resolving the contradiction between manual handling flexibility and positioning precision.
2Adaptability or versatility
If unit cells are transferred in semi-finished product state, then adaptability to different configurations is improved, but loss of time increases due to transfer process delays
Solution Approach 1:
The patent implements a continuous manufacturing process where the stacking device receives unit cells from manufacturing lines and immediately stacks them into electrode assemblies without intermediate transfer steps. The integrated design allows the stacking operation to proceed continuously, eliminating idle transfer time while maintaining adaptability through programmable stacking patterns for different battery configurations.
3Device complexity
If stacking is performed without real-time monitoring, then device complexity is reduced, but measurement precision deteriorates making it difficult to grasp folding positions
Solution Approach 1:
The patent incorporates sensors and detection devices in the stacking mechanism that provide real-time feedback on unit cell positioning and folding status. This feedback system monitors the stacking process, detects positioning errors, and enables corrective actions, thereby achieving high measurement precision without requiring overly complex external monitoring systems.
Data Source
AI summary
Provided is a system for manufacturing a secondary battery including: a positive electrode cell manufacturing line having a positive electrode single cell, on which a positive electrode tab is processed on one end of a positive electrode and a first separator is combined on one surface of the positive electrode, is continuously manufactured; a negative electrode cell manufacturing line having a negative electrode single cell, on which a negative electrode tab is processed on one end of a negative electrode and a second separator is combined on one surface of the negative electrode, is continuously manufactured; and a stacking part alternately receiving positive electrode single cells and negative electrode single cells respectively from the positive electrode cell manufacturing line and the negative electrode cell manufacturing line to stack the positive electrode single cells and the negative electrode single cells up to a predetermined layer, thereby forming a stack cell.