Electrode Stack Lamination With Induction Heating for Uniform Adhesion
Solution Overview
Problem
The existing methods for manufacturing electrode assemblies, particularly the stack and folding-type, face challenges in achieving uniform adhesive force between electrodes and separators due to non-uniform heat and pressure application, leading to inconsistent performance.
Innovation Solution
The method involves inductively heating the stack using an induction heating coil, followed by a standby period to allow heat distribution, and subsequent heating and pressing, with additional electrode tab heating to ensure uniform temperature and adhesive force across the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat and pressure are applied to bond electrodes and separator in the stack, then adhesive force between electrodes and separator is improved, but manufacturing time and energy consumption increase significantly
Solution Approach 1:
The invention changes the heating method from conventional slow heating to induction heating, which rapidly heats the stack to the required temperature. This parameter change in heating speed and method reduces the time required for the bonding process while maintaining the necessary adhesive force between electrodes and separator.
Solution Approach 2:
The invention replaces the conventional mechanical heating system with an induction heating system that uses electromagnetic fields to generate heat directly within the stack. This substitution eliminates the need for slow conductive heating through fixtures and significantly reduces manufacturing time while achieving the required bonding strength.
2Strength
If heat and pressure are applied to bond electrodes and separator, then adhesive force is improved, but uniformity of adhesive force across different stacked positions deteriorates due to non-uniform heat and pressure distribution
Solution Approach 1:
The invention replaces conventional mechanical heating and pressing systems with induction heating and a redesigned pressing mechanism. The induction heating generates heat uniformly throughout the stack via electromagnetic fields, while the pressing mechanism applies pressure through multiple contact points, ensuring uniform adhesive force across all stacked positions including edges and centers.
Solution Approach 2:
The invention divides the heating and pressing functions into separate induction heating zones and multiple pressing contact points distributed across the stack. This segmentation allows independent optimization of heat and pressure distribution, ensuring uniform adhesive force throughout the entire stack structure.
3Productivity
If conventional heating and pressing method is used, then energy consumption is high, but manufacturing speed is slow
Solution Approach 1:
The invention replaces conventional thermal conduction heating with induction heating that uses electromagnetic fields to generate heat directly within the stack material. This substitution dramatically reduces energy consumption and heating time, thereby increasing manufacturing speed while maintaining energy efficiency.
Solution Approach 2:
The invention implements continuous induction heating and pressing operations without intermediate cooling or adjustment steps. The electromagnetic field heating continues uniformly throughout the process, maintaining optimal bonding conditions continuously and reducing total manufacturing time and energy consumption.
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 approach significantly reduces the manufacturing time and ensures uniform performance of the electrode assembly by maintaining consistent adhesive force and air permeability, enhancing energy density and withstand voltage.
Implementation Method 1
performing induction heating by inductively heating the stack
Implementation Method 2
heating and pressing the inductively heated stack by a heating and pressing unit
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The present invention relates to an electrode assembly, a method for manufacturing the same, and a manufacturing apparatus therefor.