Battery Electrode Stacking With Separator Damage Detection
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Solution Overview
Problem
Existing methods for manufacturing secondary battery electrodes can cause damage to the separator during the stacking process, leading to reduced quality due to potential contact between the anode and cathode.
Innovation Solution
A method and system for manufacturing electrodes that includes forming extended portions on the separator to detect damage using cameras, ensuring the edges of these portions are offset, and using a gripper to fold the separator with anode and cathode alternately placed between layers, thereby preventing separator damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the separator is folded in a Z-shape and anodes and cathodes are alternately inserted during stacking, then the cell stack can be manufactured efficiently, but the separator may be damaged during the stacking process causing anode and cathode to face each other
Solution Approach 1:
The patent applies preliminary action by pre-forming extended portions on the separator before the stacking process. These extended portions are created in advance to serve as protective features that will prevent damage during subsequent stacking operations. The extended portions are formed by cutting or removing material from the separator to create protruding sections that will interact with the stacking mechanism to protect the separator's integrity.
Solution Approach 2:
The extended portions on the separator act as intermediaries between the stacking mechanism and the separator body. These protruding portions engage with the stacking equipment or serve as alignment features that distribute forces evenly during stacking, preventing direct contact that could damage the separator. The extended portions mediate the interaction between the stacking process and the separator, protecting the critical separation function.
2Measurement precision
If cameras are used to detect separator damage by counting edges, then the quality control is improved, but the device complexity increases
Solution Approach 1:
The patent applies the color changes principle by using optical detection (cameras) to identify structural features of the separator. The extended portions on the separator create distinct visual patterns or edge configurations that can be detected by cameras. By designing the separator with features that have distinct optical characteristics (edges, protrusions), the system can use simple image processing to detect damage without requiring complex inspection equipment.
Data Source
AI summary
A method for manufacturing an electrode of a battery includes manufacturing a cell stack, wherein an anode, a separator, a cathode, and a separator are repeatedly stacked in a stack direction in a predetermined number of layers, and determining, by a camera, whether the separator stacked in the cell stack is damaged. An electrode and a secondary battery including the electrode are described as well.