Electrode Stack Heat Press Sequencing to Prevent Deformation
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Solution Overview
Problem
Existing electrode assembly manufacturing methods face issues with cell damage and deformation during the stacking process, particularly due to distortion and misalignment of electrodes and separators.
Innovation Solution
A method involving a primary heat press operation with a gripper to secure the electrode stack, followed by pre-heating and a secondary heat press operation under controlled temperature and pressure conditions, ensuring uniform bonding of electrodes and separators without excessive heat and pressure accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat and pressure are applied to bond electrodes and separators, then bonding strength is improved, but damage and deformation of components occur
Solution Approach 1:
The bonding process is divided into multiple sequential stages: initial stacking, first heat pressing at lower temperature, cooling period, second heat pressing at higher temperature, and final cooling. Each stage applies different temperature and pressure conditions to achieve progressive bonding without overwhelming the components, thus resolving the contradiction between achieving strong bonding and preventing damage.
Solution Approach 2:
The electrodes and separators are pre-stacked in the correct configuration before any heat pressing occurs. This preliminary arrangement ensures proper alignment and positioning, allowing subsequent heat pressing to bond components effectively without causing misalignment or deformation that would occur if heating were applied during stacking.
2Manufacturing precision
If individual heat and press operations are performed at each stacking level, then bonding uniformity is improved, but heat and pressure accumulation damages lower separators
Solution Approach 1:
The heat pressing process uses periodic action with distinct phases: a first heat pressing stage at lower temperature, followed by a cooling period where no heat or pressure is applied, then a second heat pressing stage at higher temperature, and final cooling. This periodic approach allows heat dissipation between stages, preventing accumulation damage while achieving uniform bonding through multiple controlled exposures.
Solution Approach 2:
The process changes temperature and pressure parameters dynamically across different stages. The first heat pressing uses lower temperature and pressure, the second heat pressing uses higher temperature and pressure, with cooling periods in between. These parameter variations enable effective bonding at each stage without causing cumulative damage from sustained high heat and pressure.
3Device complexity
If the stack is not secured during heat press operation, then device complexity is reduced, but electrode position distortion occurs
Solution Approach 1:
A securing mechanism acts as an intermediary between the heat pressing apparatus and the electrode stack. This mediator holds the stack in fixed position during heat pressing operations, preventing distortion and misalignment, while allowing the heat and pressure to be effectively transmitted to bond the components. The securing mechanism is released after bonding, completing its intermediary function.
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 reduces the likelihood of damage and deformation, enhances uniformity in adhesive force and air permeability, and improves energy density by minimizing deviations in the manufacturing process.
Implementation Method 1
heating and pressing the stack
Implementation Method 2
pressing the stack
Implementation Method 3
engaging the electrode stack with a gripper to secure a position of the electrode stack
Data Source
Figure 1~3
Figure 4
Figure 5~6
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; then performing a pre-heating operation on the electrode stack; and then performing a secondary heat press operation on the electrode stack. The pre-heating operation may include applying heat and pressure to the electrode stack for a time period from 10 seconds to 40 seconds under a pressure condition from 0.5 MPa to 2 MPa and under a temperature condition from 50°C to 85°C. The pressure condition applied in the pre-heating operation may include applying a lower pressure than that applied in the primary and secondary heat press operations. The primary heat press operation may include engaging the electrode stack with a gripper to secure a position of the electrode stack, which gripper may be disengaged from the electrode stack before performing the pre-heating operation.