Electrode Web Overlay Alignment for Faster 3D Battery Assembly
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Solution Overview
Problem
The production of three-dimensional secondary batteries faces challenges in manufacturing efficiency, cost, and defect reduction, as existing techniques often compromise productivity and longevity to achieve improved cycle life.
Innovation Solution
A process and system for merging webs of base material with weakened patterns and conveying features to align and overlay electrode components, such as anodes, cathodes, and separators, using a receiving member with projections to facilitate precise alignment and stacking, enhancing the speed of manufacture while maintaining battery capacity and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precision manufacturing techniques are used to produce three-dimensional secondary batteries, then battery cycle life and longevity are improved, but productivity and manufacturing cost deteriorate
Solution Approach 1:
The manufacturing process is divided into distinct segments: web preparation with weakened patterns, sequential overlay of electrode components (anode, separator, cathode), and localized joining at cut lines. This segmentation allows each step to be optimized independently, maintaining precision for longevity while enabling continuous high-speed production through automated web handling and rapid cutting operations.
Solution Approach 2:
Weakened patterns are pre-formed in the separator and electrode webs before assembly, creating predetermined fracture lines that guide subsequent cutting operations. This preliminary action ensures precise component alignment and separation without requiring complex real-time control during manufacturing, thereby maintaining both product quality and production speed.
2Productivity
If existing manufacturing techniques are used for three-dimensional secondary batteries, then production can be maintained, but defects increase and manufacturing efficiency decreases
Solution Approach 1:
The separator web acts as an intermediary carrier that integrates multiple functions: it provides electrical insulation between electrodes, contains weakened patterns for precise cutting, and serves as a temporary substrate for overlaying electrode components during assembly. This intermediary structure enables defect-free manufacturing by ensuring proper component alignment and preventing direct contact between opposing electrodes throughout the high-speed production process.
Solution Approach 2:
The invention replaces complex mechanical alignment and positioning systems with a simplified web-based assembly approach. Electrode components are aligned through predetermined weakened patterns and overlay geometry rather than requiring precision mechanical guides, significantly reducing manufacturing complexity and defect rates while maintaining high production efficiency.
3Quantity of substance
If three-dimensional battery architecture is implemented, then battery capacity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Multiple manufacturing functions are merged into a single integrated web overlay process: component alignment, assembly, and separation are achieved through the combined action of weakened patterns, adhesive layers, and sequential web overlay. This merging eliminates the need for separate alignment and positioning operations, reducing manufacturing complexity while enabling three-dimensional battery architectures with enhanced capacity.
Solution Approach 2:
The invention transitions from traditional two-dimensional planar battery assembly to three-dimensional stacked architecture by overlaying electrode webs in multiple layers. The weakened patterns extend through the thickness dimension, enabling precise cutting and separation of stacked components. This dimensional transition increases battery capacity by utilizing vertical space while maintaining manufacturing simplicity through pattern-based alignment.
Data Source
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AI summary
A process for merging webs for the production of an electrode assembly for a secondary battery, the process comprising: moving a first web comprising a population of first components for electrode sub-units, the first components delineated by corresponding weakened patterns, and a population of first conveying features. Moving a second web comprising a population of second components for the electrode sub-units, the second components delineated by corresponding weakened patterns, and a population of second conveying features. Conveying a receiving member, the receiving member comprising a plurality of projections. Receiving the first web on the receiving member. Overlaying, the second web on the first web such that the first components are aligned with the second components and the conveying features of the second web are engaged by the plurality of projections on the receiving member. The second web merge location being spaced from the first web merge location.