Electrode Assembly Zigzag Folding for Stable High-Speed Stacking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional methods for manufacturing stacked or stacked/folding type electrode assemblies are complex, leading to inefficiencies, gaps between electrodes and separators, and risks of electrode movement during stacking, which affect manufacturing efficiency and product durability.
Innovation Solution
An electrode assembly folding apparatus and method that employs a horizontal zigzag stacking process, utilizing a holding unit with a suction mechanism to stabilize electrodes, and a detection unit for precise positioning, enabling efficient and damage-free folding of electrode assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional sequential stacking method is used to manufacture electrode assemblies, then the manufacturing process can be implemented with basic equipment, but the manufacturing procedure becomes complicated and generates unnecessary gap space between electrode and separator
Solution Approach 1:
The patent merges the stacking and folding operations into a single integrated process. The electrode assembly is stacked and folded simultaneously in one continuous operation, eliminating the separate folding step required in conventional methods. This integration simplifies the manufacturing procedure while ensuring tight contact between electrodes and separators, preventing gap formation.
Solution Approach 2:
The patent applies preliminary folding actions to the electrode assembly during the stacking process itself. Rather than stacking complete flat assemblies and then folding them, the folding is initiated during stacking, ensuring that the electrodes and separators are properly aligned and contacted from the beginning, preventing gap formation.
2Productivity
If zigzag stacking method is used to manufacture electrode assemblies, then the manufacturing speed can be improved, but the cut electrodes must be separately stored and there is a risk that the supplied electrodes will move during the stacking process
Solution Approach 1:
The patent introduces a guiding mechanism that acts as an intermediary between the electrode supply and the stacking area. This guide structure receives cut electrodes and directs them along a controlled path to the stacking position, preventing random movement and ensuring precise positioning. The guide mechanism maintains electrode stability while allowing continuous high-speed stacking.
3Device complexity
If conventional stacking method is used for manufacturing battery cell with long length, then the manufacturing process is simple, but it is difficult to control a tension of the separator and the progress speed is slow
Solution Approach 1:
The patent employs dynamic tension control mechanisms that automatically adjust separator tension during the stacking process. Sensors detect separator tension in real-time and feedback control systems adjust the feeding speed and stacking pressure dynamically. This enables high-speed manufacturing of long battery cells while maintaining proper separator tension and preventing defects.
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 simplifies the folding process, reduces equipment scale, prevents electrode movement, and maximizes production speed while improving product quality and durability.
Implementation Method 1
a holding unit (230) that holds a first unit body (101) supplied in a state in which a second unit body (102) is folded in a zigzag shape to one side in the longitudinal direction of the electrode assembly (100)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electrode assembly folding apparatus for folding an electrode assembly in a zigzag shape according to one embodiment of the present disclosure includes: a supply unit for supplying the electrode assembly that comprises two sheet-shaped separators, a second electrode continuously located between inside surfaces of the separators facing each other, and a first electrode alternately located up and down on outside surfaces of the two separators, wherein a first unit body and a second unit body are alternately connected to each other, wherein the first electrode of the first unit body is located on an upper side and the first electrode of the second unit body is located on a lower side, a holding unit that holds and transfers the first unit body supplied from the supply unit, and a stack unit that stacks the first unit body transferred by the holding unit.