Electrode Stack Lamination With Simultaneous Heat and Pressure
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Solution Overview
Problem
Existing electrode assembly manufacturing processes suffer from separate heating and pressing zones, leading to damage and inadequate adhesion between electrodes and separators, without effectively simplifying the process.
Innovation Solution
An integrated method involving simultaneous application of heat and pressure using a series of adjustable heating rollers to laminate electrodes and separators, with varying temperatures and pressures, followed by cold-rolling to stabilize the thermoplastic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heating and pressing zones are separated, then heating can be performed, but the pressing zone length is shortened causing high pressure damage
Solution Approach 1:
The patent combines the heating zone and pressing zone into a single integrated zone, allowing simultaneous heating and pressing operations. This eliminates the need for separate zones, maintains adequate pressing zone length, and prevents high pressure damage while achieving effective lamination through coordinated thermal and mechanical action.
2Temperature
If heating and pressing zones are separated, then heating can be performed, but separate space must be provided increasing device complexity
Solution Approach 1:
The patent integrates heating and pressing functions into a single zone with unified structural components, eliminating the need for separate heating zone, pressing zone, and associated transfer mechanisms. This reduces device complexity, minimizes space requirements, and simplifies the overall manufacturing system while maintaining both heating and pressing capabilities.
3Ease of manufacture
If separate heating and pressing processes are used, then process steps can be defined, but lamination efficiency is reduced
Solution Approach 1:
The patent enables continuous simultaneous heating and pressing operations within a single zone, eliminating the sequential nature of separate processes. The electrode assembly undergoes both thermal treatment and mechanical compression concurrently in one continuous operation, significantly improving lamination efficiency and productivity while maintaining process control.
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 minimizes damage and enhances adhesion between electrodes and separators, simplifies the manufacturing process, and improves product quality by uniformly distributing pressure and adjusting material states.
Implementation Method 1
a process of melting a thermoplastic material of the separator sheet and a thermoplastic material of the electrode is performed
Implementation Method 2
a process of melting a thermoplastic material of the separator sheet and a thermoplastic material of the electrode is performed
Implementation Method 3
the separator sheet and the electrode, which are in a stacked state, are laminated while passing through a pressing zone using pressing rolls, whereby the electrode and the separator sheet are adhered to each other
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to an electrode assembly manufacturing method according to the present invention including a step of stacking an electrode and separator to form an electrode stack and a step of laminating the electrode stack while heating the electrode stack in order to manufacture an electrode assembly having increased force of coupling between the electrode and the separator while preventing damage to the electrode assembly.