Two-Stage Heat Pressing for Electrode Stack Alignment
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Solution Overview
Problem
The existing methods for manufacturing electrode assemblies face challenges in preventing cell damage and deformation of mechanical parts, particularly due to distortion of the electrode positions during the manufacturing process.
Innovation Solution
A method and apparatus for manufacturing an electrode assembly that involves assembling an electrode stack with separators, followed by primary and secondary heat press operations to bond the electrodes and separators without individual heating and pressing of each level, thereby preventing distortion and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If individual heating and pressing of each level is performed, then bonding strength is improved, but manufacturing time increases and deformation occurs
Solution Approach 1:
The patent combines multiple individual heating and pressing operations into a single simultaneous heat press operation. The heat press apparatus applies heat and pressure to the entire electrode assembly at once, bonding all levels concurrently rather than sequentially. This merging of operations reduces manufacturing time while maintaining bonding strength through uniform thermal and mechanical application across the entire assembly.
2Quantity of substance
If electrodes are stacked with separators in zigzag manner, then energy density is improved, but electrode position distortion occurs
Solution Approach 1:
The patent implements preliminary positioning actions before the heat press operation. The electrode assembly is carefully stacked in the desired zigzag configuration with proper alignment of electrodes and separators. Positioning fixtures or guides may be used to maintain correct electrode positions before applying heat and pressure. This preliminary positioning ensures that the high-energy-density zigzag structure is achieved without subsequent distortion during the bonding process.
3Device complexity
If heat press operation is performed without gripping, then device complexity is reduced, but electrode assembly deformation occurs
Solution Approach 1:
The patent segments the heat press apparatus into distinct functional components: a gripping mechanism that holds the electrode assembly and a pressing mechanism that applies heat and pressure. The gripper is divided into multiple fingers or clamps that can independently secure different parts of the assembly. This segmentation allows the gripping function to be performed effectively without requiring an overly complex integrated system, maintaining simplicity while preventing deformation through distributed contact points.
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 effectively prevents cell damage and deformation, ensures uniform adhesive force, air permeability, and thickness of the electrode assembly, and reduces manufacturing time while improving energy density.
Implementation Method 1
heat and pressure may be applied to the electrode stack as part of the primary heat press operation
Implementation Method 2
pressure may be applied to the electrode stack as part of the primary heat press operation
Data Source
AI summary
An electrode assembly manufacturing method includes the steps of: assembling an electrode stack; performing a primary heat press operation on the electrode stack while engaging the electrode stack with a gripper; and then performing a secondary heat press operation on the electrode stack while the gripper is disengaged from the electrode stack. The secondary heat press operation may include applying heat and pressure to the electrode stack for a time period from 5 seconds to 60 seconds under a temperature condition from 50° C. to 90° C. and under a pressure condition from 1 Mpa to 6 Mpa. The step of assembling the electrode stack may include alternately stacking first and second electrodes on an elongated separator sheet, and sequentially folding the separator sheet over a previously-stacked one of the electrodes before a subsequent electrode is stacked. An apparatus for performing the manufacturing method is also disclosed.