Electrode Winding Collector Lug Alignment via Variable Spacing
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Solution Overview
Problem
In the production of electrode windings, fluctuations in electrode thickness lead to significant radial offset of collector lugs, causing misalignment and inefficiencies in the winding process, particularly in secondary batteries and capacitors with winding structures.
Innovation Solution
A method involving the formation of flat collector lugs at varying distances on the electrodes and optional contour cutting, combined with real-time sensor monitoring and data processing to correct lug positions and contours, ensuring precise overlapping of collector lugs in the winding sequence, thereby maintaining uniformity and minimizing offset.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If collector lugs are arranged at uniform distances on the electrode strip, then the manufacturing process is simple, but radial offset occurs in the winding due to increasing radius
Solution Approach 1:
The patent applies local quality by varying the spacing of collector lugs along the electrode strip according to the local radius of the winding. Collector lugs are spaced more closely at the inner radius and more widely at the outer radius, ensuring that all collector lugs align radially when wound, despite the changing radius throughout the winding process.
Solution Approach 2:
The patent implements dynamics by making the collector lug spacing adaptive rather than static. The spacing is dynamically adjusted based on the winding radius at each position, allowing the system to compensate for the increasing radius and maintain precise radial alignment of collector lugs throughout the winding.
2Adaptability or versatility
If electrode thickness fluctuates within tolerances, then manufacturing variability is acceptable, but collector lug offset increases significantly in windings with many turns
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-setting the non-uniform spacing of collector lugs based on the expected winding radius profile. This preliminary arrangement compensates for thickness variations before winding occurs, ensuring that even with acceptable thickness tolerances, the collector lugs will align radially in the finished winding.
Solution Approach 2:
The patent implements feedback by using sensors to detect the actual position and thickness of the electrode strip in real-time during manufacturing, and using this information to dynamically adjust the spacing of collector lugs. This closed-loop control ensures precise radial alignment despite variations in electrode thickness.
3Ease of manufacture
If collector lugs are grouped to overlap in a stack-like arrangement, then welding is simplified, but the winding process becomes more complex
Solution Approach 1:
The patent applies asymmetry by deliberately creating an asymmetric spacing pattern for collector lugs that results in symmetric radial alignment when wound. The asymmetric spacing on the flat electrode strip transforms into a symmetric overlapping arrangement in the cylindrical winding, simplifying welding while the winding process itself becomes the mechanism that creates the symmetry.
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 ensures minimal offset and optimal alignment of collector lugs, enhancing the uniformity and efficiency of the winding process, even with fluctuations in electrode thickness, by using a closed-loop control method and multiple lasers for precise cutting and contour adjustment.
Implementation Method 1
at least one sensor that determines at least one of the parameters... and a data-processing and control device that detects measurement results of the at least one sensor and, depending on said measurement results, prespecifies... to the means for forming the flat collector lugs... and/or supplies a corrected prespecified contour value to the means for cutting the contour
Data Source
AI summary
A method produces electrode windings, in which method a strip- or ribbon-like anode and a strip- or ribbon-like cathode are provided and flat collector lugs are formed on at least one longitudinal side of the anode and of the cathode at varying distances and/or contours are cut into the longitudinal sides of the electrodes. The anode and the cathode are wound up together with a strip- or ribbon-like separator to form a winding with the sequence anode/separator/cathode. The method is distinguished, in particular, in that the process of forming collector lugs and/or of cutting contours and the process of winding up overlap with respect to time.