Electrode Assembly Stacking with Laser-Guided Separator Alignment
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Solution Overview
Problem
Existing methods for manufacturing electrode assemblies face challenges in accurately aligning electrodes during stacking due to the difficulty in determining the precise position of subsequent electrodes when they are covered by separator sheets, leading to potential defects and process delays.
Innovation Solution
A method involving the use of a laser beam to mark the positions of electrodes, with a laser oscillator and height adjusting device to ensure accurate alignment of positive and negative electrodes, facilitated by a separator sheet that is integrally formed, allowing for continuous alignment without additional complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a separator sheet is covered above an electrode when the electrode is disposed, then the electrode assembly can be stacked, but it becomes difficult to determine whether the following electrode is aligned at an accurate position
Solution Approach 1:
The patent applies preliminary action by pre-marking the separator sheet with the position of the underlying electrode before the next electrode is placed. This marking is done in advance during the stacking process, allowing the subsequent electrode to be aligned accurately without needing to see the original electrode position through the covering separator.
Solution Approach 2:
The patent uses a laser mark as an intermediary element between the covered electrode and the next electrode to be placed. The laser mark on the separator sheet serves as a visible indicator that mediates the alignment process, enabling accurate positioning without direct visual access to the covered electrode.
2Manufacturing precision
If alignment of electrodes is checked every time they are stacked, then alignment accuracy can be ensured, but the process becomes delayed and complicated
Solution Approach 1:
The alignment information is prepared in advance by marking the separator sheet with laser during the electrode placement process itself, rather than performing separate alignment checks after stacking. This preliminary marking integrates the alignment function into the stacking process, eliminating additional inspection time.
Solution Approach 2:
The separator sheet serves itself by being marked with alignment information that automatically guides the placement of subsequent electrodes. The system uses the separator itself as the reference marker, eliminating the need for external alignment tools or additional inspection processes.
3Reliability
If the thickness of the laser beam is large, then the positioning can be more robust, but the alignment precision between electrodes decreases
Solution Approach 1:
The patent applies local quality by using a laser beam with thickness specifically matched to the gap between electrodes. Rather than using a uniformly thick beam for all applications, the laser beam dimensions are locally optimized to correspond exactly to the electrode spacing, providing both sufficient coverage for reliability and precise edge definition for alignment accuracy.
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
Enables precise alignment of electrodes in the electrode assembly process, preventing defects and simplifying the manufacturing process by ensuring accurate positioning without additional steps.
Implementation Method 1
a laser beam is irradiated to indicate positions at which the positive electrode and the negative electrode are disposed
Data Source
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AI summary
A manufacturing method of an electrode assembly in which a positive electrode and a negative electrode are alternately stacked and a separator is positioned between the positive electrode and the negative electrode according to an embodiment of the present invention includes: a first step of disposing the positive electrode above a first separator; a second step of disposing a second separator above the positive electrode to cover the positive electrode; a third step of disposing a negative electrode above the second separator; and a fourth step of disposing a third separator above the negative electrode to cover the negative electrode. In the first step and the third step, a laser beam is irradiated to indicate positions at which the positive electrode and the negative electrode are disposed.