Electrode Stacking Layout for Faster, Accurate Jelly Roll Assembly
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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 result 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 involves using two tables with motors to precisely position and stack electrodes and separators, ensuring stability and accuracy by unwinding separators from reels and using headers to position electrodes correctly, thereby improving the stacking speed and reducing positional deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a table on which electrode assemblies is stacked is moved to increase stacking speed, then productivity is improved, but electrodes deviate from their right positions and stability deteriorates
Solution Approach 1:
The patent divides the stacking system into two separate tables (first table and second table) instead of moving a single table. The first table remains stationary while the second table moves, allowing independent control of each table's function. This segmentation enables the stationary first table to maintain position accuracy while the moving second table increases stacking speed.
Solution Approach 2:
The patent introduces a separator as an intermediary element that is unwound from a separator reel and positioned between electrodes. The separator acts as a mediator that maintains electrode spacing and position stability during the stacking process, preventing electrodes from deviating even when tables are in motion.
2Productivity
If stacking process is accelerated to improve productivity, then manufacturing efficiency increases, but electrode position accuracy deteriorates
Solution Approach 1:
The patent implements preliminary positioning actions by using electrode headers to precisely position electrodes on both tables before the stacking operation begins. The separator is also pre-positioned from the separator reel to ensure correct placement. These preliminary actions establish accurate electrode positions before acceleration occurs, maintaining precision during high-speed manufacturing.
Solution Approach 2:
The patent employs motors to control the movement of the second table and separator reel, enabling precise control and adjustment of positioning during the stacking process. The motorized system provides feedback control to maintain electrode position accuracy even when operating at accelerated stacking speeds.
Data Source
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AI summary
An electrode assembly manufacturing apparatus and method according to one embodiment of the present invention may comprise: 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.