Electrode Assembly Stacking via Radical Unit Heating
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Solution Overview
Problem
The manufacturing of stack/folding-type batteries faces challenges in precise alignment and stacking stability due to the complexity of the process, and existing methods using fixing tapes can detach and increase the thickness of the electrode assembly, degrading capacity efficiency.
Innovation Solution
A method involving the sequential stacking of a four-layer radical unit structure, adhered by heating and pressing, to improve stacking stability without the need for fixing tapes, ensuring precise alignment and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If fixing tape is used to improve stacking stability, then stacking stability is improved, but the electrode assembly thickness increases and capacity efficiency degrades
Solution Approach 1:
The invention extracts and eliminates the fixing tape from the electrode assembly structure. Instead of adding a fixing tape layer, the patent uses the separator's own adhesive properties and the stacking process design to achieve stability without the additional thickness-causing component.
Solution Approach 2:
The invention uses the separator as an intermediary element that provides both its original function (isolating electrodes) and an additional function (providing adhesive bonding between radical units). The separator acts as a mediator that eliminates the need for separate fixing tape while maintaining stacking stability.
2Stability of the object's composition
If fixing tape is used to improve stacking stability, then stacking stability is improved, but the fixing tape may detach and manufacturing reliability decreases
Solution Approach 1:
The invention extracts the problematic fixing tape component entirely from the system, eliminating the reliability issues associated with tape detachment. The stacking stability is achieved through alternative means that do not involve separate adhesive tapes.
Solution Approach 2:
The separator performs multiple functions including its original electrode isolation role and an additional bonding function. This self-service approach eliminates the need for separate fixing components that could detach, as the separator inherently provides both structural and adhesive functions.
3Ease of manufacture
If multiple lamination apparatuses and folding apparatuses are used for stack/folding-type batteries, then electrode assembly can be manufactured, but the manufacturing process becomes significantly complicated
Solution Approach 1:
The invention merges multiple manufacturing functions into a single stacking apparatus. By designing the radical unit structure and stacking process appropriately, the patent combines lamination and folding operations that would traditionally require separate apparatuses into one integrated stacking process.
Solution Approach 2:
The invention segments the electrode assembly into standardized radical units with four-layer structures. This segmentation allows for simplified repetitive stacking operations rather than complex one-piece manufacturing, reducing the need for multiple specialized apparatuses.
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 method enhances the stacking stability of electrode assemblies by adhering radical units through heating and pressing, maintaining precise alignment and improving capacity efficiency by eliminating the thickness issues associated with fixing tapes.
Implementation Method 1
the radical units are adhered to each other by heating and pressing an outermost one of the radical units
Implementation Method 2
heating and pressing an outermost one of the radical units
Data Source
AI summary
Provided is an electrode assembly manufacturing method including a radical unit manufacturing stage in which a radical unit having a four-layer structure is manufactured by sequentially stacking a first electrode, a first separator, a second electrode, and a second separator, and a radical unit stacking stage in which the radical unit as a unit is repeatedly stacked to manufacture an electrode assembly, and whenever a predetermined number of radical units are stacked, the radical units are adhered to each other by heating and pressing an outermost one of the radical units.