Electrode Assembly Separator Tensioning for Precise Cut Edges

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Solution Overview

Problem

The existing methods for manufacturing electrode assemblies in secondary batteries face challenges in improving the quality of the separator cut-out surface and the efficiency of the manufacturing process.

Innovation Solution

An apparatus is introduced that includes a stacking plate with a first stacking region, an actuator to move the stacking plate, an electrode assembly release unit to provide tension to the separator, a separator fixing unit to press the separator, and a separator cutting unit to cut the separator, with specific configurations to enhance the precision and efficiency of the cutting process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the separator is cut without tension and fixing, then the cutting process is simple, but the cut-out surface quality deteriorates with increased unevenness

Engineering Contradiction:

Improveseparator cut-out surface qualityVSAvoidcutting process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The separator fixing unit presses the separator onto the stacking plate before the cutting operation, and the electrode assembly release unit applies tension to the separator in advance. These preliminary actions stabilize the separator and prevent movement during cutting, ensuring high cut-out surface quality without requiring complex real-time control mechanisms.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cutting system is divided into independent functional units: the separator fixing unit for stabilization, the electrode assembly release unit for tensioning, and the separator cutting unit for cutting. This segmentation allows each unit to perform its specific function optimally while maintaining overall system simplicity.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If the separator is not fixed and tensioned during cutting, then the manufacturing process is efficient, but the cut-out surface quality deteriorates

Engineering Contradiction:

Improveseparator cut-out surface qualityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The separator fixing unit and electrode assembly release unit operate simultaneously during the cutting process. The fixing unit presses the separator onto the stacking plate while the release unit applies tension, both actions occurring in parallel to stabilize the separator without adding sequential steps, thus maintaining manufacturing efficiency while ensuring cut-out surface quality.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If the stacking plate does not move precisely, then the device structure is simple, but the alignment and cutting precision deteriorates

Engineering Contradiction:

Improvestacking and cutting alignment precisionVSAvoidactuator control system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The first actuator controls the stacking plate's vertical movement with feedback mechanisms that detect the position and adjust accordingly. This ensures precise alignment during stacking and positioning for cutting, maintaining high manufacturing precision while using a relatively simple actuator structure through intelligent control.

Inventive Principle:

Principle #23Feedback

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 apparatus improves the quality of the separator cut-out surface by ensuring a smooth and precise cutting process, reducing unevenness, and enhances the manufacturing efficiency by optimizing the movement and alignment of electrode components.

Implementation Method 1

provide tension to the separator by pulling the preliminary electrode assembly

Methodology Applied

Scientific EffectTension: Tension

Implementation Method 2

press the separator in a state in which only the separator remains on the stacking plate

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS12494547B2Apparatus for manufacture of electrode assembly and electrode assembly manufactured by the same

Publication Date: 2025.12.09 SK ON CO LTD

AI summary

An apparatus for manufacturing an electrode assembly includes a stacking plate including a first stacking region in which a cathode plate, an anode plate and a separator are stacked; a first actuator connected to the stacking plate and configured to move the stacking plate; an electrode assembly release unit configured to, in a state in which a separator is present on an uppermost portion of a preliminary electrode assembly formed by stacking the cathode plate, the anode plate, and the separator, provide tension to the separator by pulling the preliminary electrode assembly to the outside of the stacking plate; a separator fixing unit configured to press the separator in a state in which only the separator remains on the stacking plate; and a separator cutting unit configured to cut the separator on the stacking plate after the separator fixing unit presses the separator.