Electrode Strand Supply with Pre-Cut Segments for Fast Battery Stacking
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Solution Overview
Problem
Existing methods for producing battery cells face challenges in cycle time, process control, and flexibility due to complex laser cutting on three-dimensional surfaces and heat-related tolerance issues during electrode lamination.
Innovation Solution
A method and device for providing electrode strings by cutting electrode segments on a flat surface using a guided laser beam, followed by independent lamination on hard surfaces, with a transport system that adjusts spacing and uses vacuum heating rollers for precise positioning and lamination, enabling efficient and flexible production of monocells and cell stacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser cutting is performed on three-dimensional surfaces during electrode lamination, then the electrodes can be processed in a continuous manner, but thermal expansion errors and tolerance issues occur due to heat-related distortion
Solution Approach 1:
The patent separates the cutting operation from the lamination operation in time and space. Electrode segments are cut in advance on flat surfaces before lamination, eliminating thermal expansion errors during the critical lamination process. This preliminary action ensures high cutting precision without compromising continuous production capability.
Solution Approach 2:
The continuous lamination process is segmented into discrete steps: pre-cutting electrode segments on flat surfaces, then laminating them sequentially onto the separator. This segmentation allows each operation to be optimized independently - cutting for precision on flat surfaces, lamination for continuity on the conveyor system.
2Adaptability or versatility
If complex laser cutting on three-dimensional surfaces is used, then electrode segments can be separated during lamination, but cycle time increases and process control becomes difficult
Solution Approach 1:
Electrode segments are pre-cut to final dimensions before lamination, eliminating the need for complex real-time separation during the lamination process. This preliminary segmentation action reduces cycle time and simplifies process control while maintaining the capability to produce individually spaced electrode segments.
Solution Approach 2:
Instead of separating electrode segments during lamination as in conventional processes, the patent inverts the sequence by cutting segments first on flat surfaces, then laminating them in their already-separated state. This inversion dramatically reduces cycle time and improves process control.
3Ease of operation
If electrode transfers are performed during the manufacturing process, then electrodes can be repositioned and adjusted, but the number of process steps increases and production efficiency decreases
Solution Approach 1:
Electrode segments are pre-positioned and pre-cut to exact dimensions and spacing on flat surfaces before lamination. This preliminary positioning eliminates the need for subsequent transfer and repositioning operations, maintaining ease of operation for adjustments while dramatically improving production efficiency.
Solution Approach 2:
The electrode transfer operation is completely extracted from the lamination process. By pre-positioning electrodes on flat surfaces before lamination, the patent eliminates the time-consuming transfer step while retaining the ability to adjust electrode positions during the pre-positioning phase.
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 approach reduces cycle times to 0.1 seconds per single-cell unit, eliminates the need for electrode transfers, and ensures high format flexibility with reduced thermal expansion errors, leading to efficient and reliable large-scale battery production.
Implementation Method 1
Picking up the web-shaped electrode substrate by means of a transport system having individually, independently movable transport units along a guide track
Implementation Method 2
Cutting the web-shaped electrode substrate in the cutting plane to cut off electrode segments
Implementation Method 3
vacuum heating rollers for precise positioning and lamination
Implementation Method 4
independent lamination on hard surfaces
Data Source
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AI summary
To increase process reliability and/or process speed and/or to simplify process control and/or setup, the invention provides an electrode strand supply method for supplying an electrode strand (32.1, 32.2) which has a separator track (34.1, 34.2) and electrode segments (36.1, 36.2) attached to it at a distance from one another, wherein the electrode strand supply method comprises: a) supplying a web-shaped electrode substrate (50.1, 50.2); b) receiving the web-shaped electrode substrate (50.1, 50.2) by means of a transport system (40.1, 40.2) which has individually movable transport units (62) along a guide track (60), and planar movement of the electrode substrate (50.1, 50.2) along a cutting plane (64); c) Cutting the web-shaped electrode substrate (50.1, 50.2) in the cutting plane (64) to cut electrode segments (36.1, 36.2) to cut off electrode segments (36.1, 36.2), each individually arranged on one of the transport units (62); d) to adjust the distance between the cut electrode segments (36.1, 36.2) by relative movement of the transport units (62) in order to position the electrode segments (36.1, 36.2) relative to each other; e) to provide a separator track (34.1, 34.2); f) to apply and fix the electrode segments (36.1, 36.2) positioned relative to each other on the separator track (34.1, 34.2). Furthermore, uses of the electrode string provisioning method and devices configured for carrying it out are described.