Electrode Strip Assembly Using Coupling Wheels for Faster Cell Production
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Solution Overview
Problem
Current systems for forming electrode strips in electrical energy storage devices are inefficient, costly, and have low production speeds, and they fail to meet the current production needs of the sector.
Innovation Solution
An apparatus is developed that forms an electrode strip by alternately applying anode and cathode elements on a flexible separator strip using counter-rotating coupling wheels with retaining means, preheating, and mechanical rolling, ensuring high production speed and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If current systems for forming electrode strips are used, then electrode assembly is achieved, but production speed is low and manufacturing cost is high
Solution Approach 1:
The system segments the electrode formation process into distinct functional modules: feeding mechanism for separator and electrodes, counter-rotating coupling wheels for alternating application, preheating unit, and rolling mechanism. This modular segmentation enables independent optimization of each component, improving overall production speed while maintaining manageable system complexity.
Solution Approach 2:
The preheating unit applies preliminary thermal action to the separator and electrodes before they reach the coupling wheels. This preliminary heating softens the materials, enabling easier bonding and faster assembly at the coupling stage, thereby increasing production speed without requiring overly complex high-pressure bonding systems.
2Ease of manufacture
If current electrode strip formation systems are used, then electrodes are assembled, but manufacturing cost is high
Solution Approach 1:
The counter-rotating coupling wheels utilize the inherent rotational motion and material properties to automatically position and apply electrodes alternately on opposite faces of the separator. The system leverages the materials' own characteristics (flexibility, adhesion) to achieve assembly, reducing the need for expensive auxiliary equipment and lowering manufacturing costs while maintaining high production speed.
3Device complexity
If simple and cost-effective apparatus is used, then production cost is reduced, but production speed may be compromised
Solution Approach 1:
The feeding mechanisms continuously supply separator and electrodes to the coupling wheels without interruption. The counter-rotating wheels operate in continuous alternating motion, applying electrodes on both faces simultaneously in an unbroken sequence. This continuous operation eliminates idle time and maintains high production speed despite the simplicity of the apparatus design.
Solution Approach 2:
The counter-rotating coupling wheels employ curved, rotating surfaces to transfer and apply electrodes. This curvature enables smooth, continuous material handling and bonding along the rotational path, achieving fast production speeds through rotational motion rather than complex linear positioning systems, thus maintaining apparatus simplicity.
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
The apparatus achieves a high production speed with a simple, reliable, and cost-effective formation of electrode strips for electrical energy storage devices, enhancing the manufacturing process efficiency.
Implementation Method 1
a pair of counter-rotating coupling wheels between which said separator is fed according to a median plane to the same counter-rotating coupling wheels. Preferably said feeding plane of the separator is arranged vertically. said counter-rotating coupling wheels are adapted to receive and hold on the peripheral surface alternately said anode and cathode elements, to transfer the same anode and cathode elements alternately on the opposite faces of said separator
Implementation Method 2
said coupling means comprises means adapted to preheat said separator and said anode and cathode elements up to a controlled temperature
Implementation Method 3
said coupling means comprises a pair of counter-rotating rolling cylinders, arranged downstream of said coupling wheels, whereby a mechanical rolling process of said separator, carrying applied said anode and cathode elements, is carried out to obtain said flexible strip
Data Source
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AI summary
The apparatus for forming a strip of electrodes for manufacturing electrical energy storage devices, of the type comprising a stack of electrodes formed by folding a flexible strip (2) comprising a separator (20) carrying applied, on the opposite faces, a series of anode elements (21) and a series of cathode elements (22), comprises first feeding means (10) suitable for operating the advancement of a strip of separator material (20) and second and third feeding means (30, 40) suitable for operating the advancement respectively of said anode elements (21 ) and of said cathode elements (22). The apparatus comprises means (70) of coupling said anode and cathode elements (21, 22) to said strip of separator material (20) comprising a pair of counter-rotating coupling wheels (71) between which said strip of separator material (20) is fed according to a median plane to the same counter-rotating coupling wheels (71).