Energy Cell Layer Bonding With Gravure-Printed Adhesive Patterns
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Solution Overview
Problem
Existing methods for producing energy cells face challenges in applying adhesive compositions cleanly and precisely without nozzles, leading to inhomogeneous stacks and high energy consumption due to lamination processes, limiting material choices and production efficiency.
Innovation Solution
The application of adhesive composition is done using a gravure printing roller with recesses to create precise adhesive patterns, allowing for direct adhesive bonding during the stacking process, eliminating the need for lamination and enhancing production speed and homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If lamination is used to bond layers, then bonding strength is achieved, but energy consumption increases and material choices are limited
Solution Approach 1:
The patent replaces the thermal lamination process with a mechanical adhesive application system. A gravure printing device applies adhesive composition to separator sheets in a controlled manner, eliminating the need for high-energy lamination equipment. This substitution reduces energy consumption while maintaining bonding effectiveness through the adhesive composition that sets at ambient or controlled temperatures.
Solution Approach 2:
The patent changes the bonding mechanism from thermal lamination to chemical adhesive bonding. By using adhesive compositions with specific properties (viscosity, setting time, bonding strength) that can be applied at lower temperatures and pressures, the process achieves comparable or superior bonding strength with significantly reduced energy input.
2Strength
If lamination is used to bond layers, then bonding is achieved, but material choices for separators are limited
Solution Approach 1:
By replacing thermal lamination with adhesive bonding, the patent removes the constraint that separator materials must be thermally stable and laminable. This allows use of a broader range of materials including polymers, ceramics, and composite materials that may not withstand lamination temperatures or lack the necessary surface properties for lamination.
Solution Approach 2:
The bonding mechanism changes from physical-thermal (lamination) to chemical (adhesive bonding), fundamentally expanding material compatibility. Adhesive compositions can bond to diverse surfaces through various mechanisms (van der Waals forces, chemical bonding, mechanical interlocking), enabling use of materials with diverse thermal, mechanical, and chemical properties.
3Ease of manufacture
If adhesive is applied without nozzles, then application simplicity improves, but precision and cleanliness of application deteriorates
Solution Approach 1:
The patent replaces simple but imprecise adhesive application methods (such as brush or roller application without nozzles) with a gravure printing system. This system uses a cylindrical drum with precisely engineered cells or recesses that transfer adhesive composition to the separator sheet in controlled patterns, achieving both cleanliness and precision.
Solution Approach 2:
The gravure printing drum acts as an intermediary between the adhesive source and the separator sheet. The drum's surface cells hold and precisely position the adhesive composition, ensuring clean, controlled application without direct contact between the adhesive source and the separator, thereby achieving both simplicity and precision.
4Manufacturing precision
If adhesive composition is applied precisely, then bonding homogeneity improves, but application complexity increases
Solution Approach 1:
The gravure printing device serves multiple functions: it meters the adhesive composition, patterns the adhesive on the separator sheet, and transfers the adhesive in a controlled manner. This multi-functionality achieves precise, homogeneous adhesive application without requiring a complex system of multiple separate devices for each function.
Solution Approach 2:
The gravure printing cells are designed to deliver uniform amounts of adhesive composition across the separator sheet surface. By controlling the cell geometry, depth, and distribution, the system ensures homogeneous adhesive application, which leads to consistent bonding across the entire energy cell stack.
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 method ensures secure, homogeneous bonding of energy cell layers with improved production efficiency, increased material variability, and reduced energy consumption, while maintaining precise application and quality control.
Implementation Method 1
the application of adhesive composition is done using a gravure printing roller with recesses to create precise adhesive patterns
Data Source
AI summary
A method for producing energy cells in stack form having a plurality of separator sheets and a plurality of electrodes arranged between the separator sheets, wherein the plurality of electrodes are alternately arranged anodes and cathodes. At least one electrode is fixed to at least one of the separator sheets by an adhesive bond. The adhesive composition for the at least one adhesive bond is applied by gravure printing, to provide particularly exact adhesive bonding.