Electrode Web Merging With Weakened Patterns for Precise 3D Battery Assembly
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Solution Overview
Problem
The production of three-dimensional secondary batteries faces challenges in manufacturing precision while maintaining productivity and cost, often resulting in increased defects, reduced capacity, and shortened longevity when manufacturing techniques are sped up.
Innovation Solution
A process for merging and separating electrode webs using weakened patterns and conveying features, facilitated by a receiving member with projections, and a system with alignment pins and a punch head to separate electrode sub-units, enhancing precision and alignment during the manufacturing of electrode assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manufacturing techniques are sped up to increase productivity, then productivity is improved, but manufacturing precision deteriorates resulting in increased defects and reduced battery quality
Solution Approach 1:
The patent incorporates alignment features directly into the electrode webs during manufacturing, and pre-forms weakened patterns at specific locations. These preliminary actions enable rapid assembly without compromising precision, as components are pre-prepared for quick alignment and joining during the high-speed assembly process
Solution Approach 2:
The patent introduces alignment features as intermediary elements that facilitate precise positioning during rapid assembly. These features act as mediators between the electrode webs and the assembly process, enabling high-speed manufacturing while maintaining alignment precision through standardized interface elements
2Productivity
If manufacturing techniques are sped up to increase productivity, then productivity is improved, but reliability deteriorates resulting in reduced battery longevity
Solution Approach 1:
The weakened patterns are pre-formed at locations that will become fold lines or separation points in the three-dimensional battery structure. This preliminary action ensures that critical structural features are correctly positioned before assembly, maintaining reliability even when assembly speed is increased
Solution Approach 2:
The patent replaces complex mechanical alignment and positioning systems with pre-formed alignment features and weakened patterns that guide assembly through inherent structural cues. This substitution reduces mechanical complexity and potential for error during high-speed assembly, preserving battery longevity
3Manufacturing precision
If precision manufacturing techniques are used to improve manufacturing precision, then manufacturing precision is improved, but productivity deteriorates due to increased manufacturing time
Solution Approach 1:
The patent segments the electrode webs into modular units with standardized alignment features and weakened patterns. This segmentation allows parallel processing and assembly of multiple units simultaneously, maintaining high precision through standardization while improving overall productivity through modular construction
Solution Approach 2:
The patent changes the physical state or properties of specific regions of the electrode webs by creating weakened patterns through partial cutting, scoring, or adhesive application. This parameter change enables precise positioning and controlled separation without requiring complex mechanical intervention, achieving both precision and speed
Data Source
AI summary
Production of electrodes, electrode assemblies, electrode stacks, and batteries, is disclosed herein comprising merging webs, associated devices, methods, and control such as relating to battery manufacturing. The batteries can comprise electrochemical active material. The webs can comprise weakened tear features for delineation components of the electrodes, electrode assemblies, electrode stack, and for the batteries.