Electrode Assembly Separator Bonding for Stable High-Density Stacking
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Solution Overview
Problem
Existing electrode assembly manufacturing methods face challenges in maintaining stability and maximizing capacity per unit volume, as the electrodes move during stacking, leading to decreased efficiency.
Innovation Solution
A method involving sequential stacking of electrodes with a separator in between, where the separator is heated and bonded to the electrode surfaces to fix the electrodes in place, using grippers or heaters to ensure stability and prevent movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the lamination winding method is used to bond electrodes to separator for stability, then electrode movement is prevented, but capacity per volume decreases due to separator stacking in width direction
Solution Approach 1:
The separator is divided into multiple segments corresponding to different electrode stacks. Each separator segment is independently bonded to its corresponding electrode, allowing precise positioning without excess separator material stacking in the width direction. This segmentation enables stable electrode fixation while maximizing active material density and capacity per volume.
2Quantity of substance
If the stacking method is used to increase capacity per volume, then capacity per unit volume increases, but electrode movement occurs in width direction reducing stability
Solution Approach 1:
The separator is pre-bonded to the electrode before the electrode is stacked with other components. This preliminary bonding action secures the electrode position in advance, preventing any width-direction movement during the stacking process. The electrode is then stacked onto the pre-bonded separator assembly, maintaining both high capacity per volume and electrode stability.
3Ease of manufacture
If separator is folded and stacked in zigzag shape to accommodate electrode movement, then electrode stacking is facilitated, but separator shrinkage occurs reducing effectiveness
Solution Approach 1:
The separator's physical state is changed by heating and bonding, transforming it from a flexible, shrinkable material into a rigid, fixed structure. The separator is heated to its melting or softening point, then bonded to the electrode in a flat, taut configuration. This parameter change (temperature and bonding state) prevents subsequent shrinkage while facilitating easy stacking.
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
The method enhances stability and increases capacity per unit volume by securely fixing the electrodes, preventing movement and ensuring efficient stacking.
Implementation Method 1
a step of heating the separator covered on the electrode disposed at the n layer
Implementation Method 2
the separator is heated and bonded to the electrode surfaces to fix the electrodes in place
Data Source
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Figure 1B
Figure 1C
AI summary
The present invention comprises a method for manufacturing an electrode assembly, in which a plurality of electrodes are stacked, wherein a negative electrode and a positive electrode are sequentially alternately stacked, and a separator is disposed between the negative electrode and the positive electrode, the method comprising: a step of covering a top surface of an electrode disposed at an n layer (where n is a natural number of 1 or more) by using the separator; a step of heating the separator covered on the electrode disposed at the n layer; a step of stacking an electrode, which is disposed at an n+1 layer, on the heated separator; a step of covering a top surface of the electrode, which is disposed at the n+1 layer, by using the separator; and a step of heating the separator covered on the electrode disposed at the n+1 layer. According to the present invention having the above-described structure, the separator may be bonded to the electrode, or the separators may be bonded to each other to fix the movement of the electrode, thereby improving the stability. In addition, since the separator is not stacked in the width direction, the capacity per unit volume may increase.