Electrode Feed Roll Butt Joining for Continuous Battery Production

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Solution Overview

Problem

The existing methods for replacing electrode materials in secondary battery cell production require manual intervention, leading to significant downtime and reduced productivity due to the need for operators to manually move and replace feed rolls.

Innovation Solution

An automatic replacement apparatus and method that includes a discharge unit, a pair of feed units, and material joint units to automatically connect and replace feed rolls, minimizing material loss and ensuring continuous production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If manual replacement of feed rolls is performed, then operators can replace electrode material, but production facility stops for a great deal of time and productivity is lowered

Engineering Contradiction:

Improvefeed roll replacement automationVSAvoidproduction output

Core Design Contradiction:

Extent of automationVSProductivity

Solution Approach 1:

The system prepares a new feed roll in advance (pre-positioning it in the replacement position) before the current feed roll is completely consumed. This preliminary preparation allows the replacement to occur seamlessly when the timing is right, eliminating the need for operators to manually move rolls during production stoppage.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system enables automatic feed roll replacement through automated mechanisms including robotic arms, alignment systems, and control units that coordinate the entire replacement process without human intervention. The apparatus serves itself by detecting when replacement is needed and executing the replacement automatically.

Inventive Principle:

Principle #25Self-service

2Extent of automation

If manual replacement of feed rolls is performed, then operators can replace electrode material, but a large amount of work time is required

Engineering Contradiction:

Improvefeed roll replacement automationVSAvoidreplacement operation time

Core Design Contradiction:

Extent of automationVSLoss of time

Solution Approach 1:

The new feed roll is pre-positioned and pre-aligned in the replacement position before actual replacement is needed. This preliminary action includes pre-tensioning the feed material and pre-aligning the roll axis, so that when replacement occurs, it can be completed in minimal time without manual adjustment.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces manual mechanical operations with automated mechanical systems including robotic manipulators, automated clamping mechanisms, and computer-controlled positioning systems. This substitution dramatically reduces the time required for replacement operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If feed roll replacement is performed, then continuous supply of electrode material is needed, but material loss occurs during replacement

Engineering Contradiction:

Improvecontinuous productionVSAvoidfeed material loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The system maintains continuous feed material supply by implementing an overlapping transition mechanism where the new feed roll's material is joined to the remaining material of the old roll. This ensures unbroken material flow and eliminates gaps or losses during the replacement transition.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system uses an intermediary joining mechanism (such as adhesive tape or mechanical coupling devices) to connect the end of the old feed material to the beginning of the new feed material. This intermediary element ensures seamless transition without material loss or interruption in the production process.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 automatic replacement system reduces operational time, minimizes feed material loss, and maintains continuous production by automating the process of replacing electrode material feed rolls.

Implementation Method 1

a support block including a front plate allowing the feed material to be disposed thereon and having a plurality of adsorption holes forming negative pressure

Methodology Applied

Scientific EffectNegative pressure: Pressure Drop

Implementation Method 2

The clamp may include a stationary magnet and may be coupled to the front plate formed of a metal material by magnetic force

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS20250042683A1Automatic replacement apparatus and method for feed material

Publication Date: 2025.02.06 SK ON CO LTD

AI summary

An automatic replacement apparatus for a feed material includes a discharge unit discharging a feed material to the outside, a pair of feed units disposed to be adjacent to the discharge unit and having a feed roll around which the feed material is wound, and a pair of material joint units respectively provided in the pair of feed units connecting a front end of a first feed material waiting in a first feed unit, one of the pair of feed units, and an end of a second feed material being transferred from a second feed unit, the other of the pair of feed units, to the discharge unit in a butt joint manner.