Electrode Strand Lamination Using a Reusable Single Liner Web
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Solution Overview
Problem
Existing methods for producing battery cells require multiple separate liners for each lamination step, increasing material and installation costs, energy consumption, and space requirements.
Innovation Solution
A method and device that uses a single liner web for multiple lamination steps, with the liner being reused and guided through an endless loop to prevent material adherence to lamination tools, reducing the need for separate liners and components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate liners are used for each lamination step, then process reliability is maintained, but material costs and installation costs increase
Solution Approach 1:
The patent merges multiple separate liner functions into a single continuous liner web that serves multiple lamination stations sequentially. The liner web is designed to be reused across several lamination steps, consolidating what would traditionally require multiple individual liners into one continuous component, thereby reducing material consumption while maintaining protective functionality.
Solution Approach 2:
The single liner web is designed to perform multiple functions across different lamination stations. It sequentially protects different lamination tools (first lamination tool, second lamination tool, etc.) from electrode material adhesion, making one liner component serve universal protective purposes across the entire production line rather than requiring station-specific liners.
2Reliability
If multiple separate liners are used for each lamination step, then process reliability is maintained, but installation costs increase
Solution Approach 1:
The patent consolidates multiple liner handling systems into a single integrated liner supply and guidance system. Instead of requiring separate unwinding, feeding, and winding mechanisms for each lamination station, the system uses one continuous liner web managed by centralized supply rolls and guidance devices, significantly reducing installation complexity and associated costs.
Solution Approach 2:
The liner web operates as a continuous component throughout the lamination process, eliminating the need for repeated liner changes and handling operations. The continuous liner maintains uninterrupted protective coverage across all lamination stations, reducing the complexity of liner management systems while ensuring consistent process reliability.
3Reliability
If multiple separate liners are used for each lamination step, then material protection is ensured, but energy consumption increases
Solution Approach 1:
The patent combines multiple liner handling operations into a single continuous liner web system, reducing the total energy required for liner unwinding, feeding, and winding operations. By eliminating redundant handling steps and using one continuous liner instead of multiple separate liners, the system decreases energy consumption associated with liner management while maintaining adequate material protection.
4Reliability
If multiple separate liners are used for each lamination step, then lamination protection is maintained, but space requirements increase
Solution Approach 1:
The patent consolidates multiple liner storage and handling stations into a single integrated liner web system. Instead of requiring separate storage spaces, unwinding stations, and winding stations for each lamination step, the system uses one continuous liner web managed from centralized supply rolls, significantly reducing the factory floor space required for liner management while maintaining adequate protection for all lamination operations.
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
Reduces material and installation costs, energy consumption, and space requirements while maintaining process reliability and quality by reusing a single liner web across multiple lamination stations.
Implementation Method 1
a) Laminating a first electrode material to a first separator web in a first laminating station by means of a first laminating tool with the insertion of a liner web, in particular between the (first) separator and the (first) laminating tool, to prevent the material to be laminated from adhering to the first laminating tool
Implementation Method 2
Laminating a first electrode material to a first separator web in a first laminating station by means of a first laminating tool
Data Source
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AI summary
To reduce the effort and costs of cell production in a continuous process while maintaining high quality, the invention provides an electrode strand supply method for supplying at least one electrode strand (32, 88) comprising at least one separator web (34.1, 34.2) and at least one electrode material (50.1, 50.2, 36.1, 36.2) fixed thereto, comprising a) laminating a first electrode material (50.1, 36.1) to a first separator web (34.1) in a first laminating station (46.1) by means of a first laminating tool (76.1) with the insertion of a liner web (100) to prevent the material to be laminated from adhering to the first laminating tool (76.1), b) laminating a second electrode material (50.2, 36.2) to a separator web (34.1, 34.2) in a second laminating station (46.2) using a second laminating tool (76.2) by inserting a liner (100) to prevent the material to be laminated from sticking to the second laminating tool (76.2), using the same liner (100) in steps a) and b).