Electrode Assembly Stacking With Dual Tables for Precise Alignment
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Solution Overview
Problem
The existing methods for manufacturing stack-type electrode assemblies face inefficiencies and stability issues due to the time-consuming process of stacking cathodes, anodes, and separators, which often results in electrodes deviating from their correct positions, leading to reduced productivity and increased defect rates.
Innovation Solution
An electrode assembly manufacturing apparatus and method that includes two tables with motors to manage the positioning and stacking of separators and electrodes, ensuring precise alignment and efficient stacking by unwinding separators from reels and using headers to position and move electrodes, thereby maintaining stability and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the table on which electrode assemblies are stacked is moved to increase stacking speed, then productivity is improved, but the electrodes deviate from their right positions and stability deteriorates
Solution Approach 1:
The stacking process is divided into two independent workstations: a first workstation for stacking the first electrode and separator, and a second workstation for stacking the second electrode and separator. This segmentation allows each station to operate independently with fixed tables, eliminating position deviation while maintaining high productivity through parallel operations.
Solution Approach 2:
The first electrode and separator are stacked in advance at the first workstation before the second electrode is added at the second workstation. This preliminary action allows the first half jelly roll to be prepared and fixed in position, providing a stable base for subsequent assembly without requiring movement of the stacking table.
2Productivity
If the stacking process is simplified to increase speed, then productivity is improved, but the time for stacking cathodes, anodes, and separators becomes insufficient leading to defects
Solution Approach 1:
The stacking process continues without interruption between workstations. The separator is continuously fed from the separator reel through both workstations, and the stacking operations proceed in sequence without stopping, ensuring that each layer is properly formed while maintaining high manufacturing speed.
Solution Approach 2:
The separator acts as an intermediary element that connects the first electrode and second electrode. By continuously feeding the separator through both workstations, it enables the stacking process to proceed smoothly without interruption, ensuring proper alignment and positioning of all components.
Data Source
AI summary
An electrode assembly manufacturing apparatus and method according to one embodiment of the present invention includes a first table on which a first half jelly roll is stacked; a second table on which a second half jelly roll is stacked; a separator disposed on the first table and the second table; a first separator reel unwinding the separator in a direction to the first table; a second separator reel unwinding the separator in a direction to the second table; an electrode header providing a first electrode and a second electrode to the first table and the second table; a first motor moving the separator in a direction for covering the first electrode and the second electrode provided on the first table; a second motor moving the separator in a direction for covering the first electrode and the second electrode provided on the second table; and an assembly header providing the second electrode between the first half jelly roll and the second half jelly roll.