Electrode Assembly Lamination for Separator Wrinkle Prevention

The patent applies preliminary anti-action by pre-stretching the separator in the anti-wrinkle unit before lamination. The separator is stretched in the machine direction and/or transverse direction to create tension that counteracts the folding and wrinkling forces that will occur during subsequent transfer and handling processes. This preventive measure ensures the separator maintains its flatness despite being designed with a larger area than the electrodes for adequate insulation clearance.

The patent implements preliminary action by performing the stretching and embossing operations on the separator before the actual lamination process. The anti-wrinkle unit stretches the separator and forms embossed patterns in advance, preparing the separator in an optimal state for lamination. This preliminary preparation ensures that the separator is properly tensioned and stabilized before being laminated to the electrodes, preventing future folding issues.

The patent replaces the purely mechanical stretching system with a combined mechanical-thermal system. The anti-wrinkle unit incorporates both mechanical stretching (through rollers applying tension) and thermal treatment (through heating elements). This substitution allows the separator to be stretched tightly for stability while the thermal component increases friction and adhesion, preventing slip during transfer. The embossed patterns formed thermally also increase surface friction to prevent sliding.

The patent creates a composite effect by combining mechanical tension with thermal embossing on the separator. The stretched separator surface receives embossed patterns that create a composite structure with increased surface area and friction. This composite treatment ensures the separator remains tightly stretched for stability while the embossed surface prevents slipping during handling and transfer operations.

The patent applies preliminary action by stretching the separator before forming the embossed pattern. The anti-wrinkle unit first stretches the separator in the machine direction and/or transverse direction to establish proper tension and flatness. Only after this preliminary stretching is the embossed pattern formed on the already-stretched separator. This sequence ensures the separator is stabilized against folding before the embossing process begins.

The patent replaces simple mechanical embossing with a combined mechanical-thermal embossing system. The embossed pattern is formed through both mechanical pressure and thermal treatment in the anti-wrinkle unit. This substitution allows the embossing to occur on a pre-stretched, tensioned separator, ensuring the pattern is formed on a stable, flat surface rather than on a loose, potentially folding separator.