Horizontal Electrode Strip Folding for Energy Storage
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Solution Overview
Problem
The existing methods for producing electrode stacks for energy storage in motor vehicles are complex and inefficient due to the need for precise robotic handling and limited assembly speed, as they require stacking individual electrodes and separators, which complicates the folding process.
Innovation Solution
A method and system where the electrode strip, covered with cathodes and anodes on a separator, is aligned horizontally and folded in sections or as a whole between electrodes, using grippers to create fold lines and a holder to facilitate easy integration into a stacking system, allowing for simple and energy-saving folding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual electrodes and separators are stacked using robotic handling, then precise positioning can be achieved, but assembly speed is limited and design complexity increases
Solution Approach 1:
The patent combines multiple components (separator strip, cathodes, anodes) into a single integrated electrode strip structure. The separator strip serves as a common substrate that carries both cathodes and anodes in alternating arrangement, eliminating the need for separate robotic handling of each component while maintaining precise positioning through the structured layout on the separator strip.
Solution Approach 2:
The electrode strip is divided into multiple identical sections, each containing a separator portion with cathode and anode segments. This segmentation allows the entire strip to be folded simultaneously at multiple locations to create the stacked configuration, dramatically increasing assembly speed compared to sequential stacking of individual components.
2Manufacturing precision
If individual electrodes and separators are stacked using robotic handling, then precise positioning can be achieved, but design complexity increases
Solution Approach 1:
The patent combines multiple components (separator strip, cathodes, anodes) into a single integrated electrode strip structure. The separator strip serves as a common substrate that carries both cathodes and anodes in alternating arrangement, eliminating the need for separate robotic handling of each component while maintaining precise positioning through the structured layout on the separator strip.
3Ease of manufacture
If the electrode strip is folded vertically as proposed in prior art, then folding can be achieved, but the process requires complex vertical movement and integration with production is difficult
Solution Approach 1:
Instead of folding the electrode strip vertically as proposed in prior art, the patent inverts the folding approach by performing horizontal folding. The electrode strip is folded in the horizontal plane between the electrodes, which simplifies the folding mechanism and allows direct integration with the horizontal production line for manufacturing the electrode strip.
4Productivity
If folding is performed in the vertical direction, then electrode stacking can be achieved, but integration with electrode strip production is difficult
Solution Approach 1:
Instead of folding the electrode strip vertically as proposed in prior art, the patent inverts the folding approach by performing horizontal folding. The electrode strip is folded in the horizontal plane between the electrodes, which simplifies the folding mechanism and allows direct integration with the horizontal production line for manufacturing the electrode strip.
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 simplifies the folding process, integrates it with the production of the electrode strip, and ensures secure fastening of electrodes, enabling faster and more efficient assembly of electrode stacks without damaging the electrodes.
Implementation Method 1
the electrode strip is in a horizontal plane during folding, which means that, for example, the electrode strip that was covered with the electrodes in a previous work step can be directly fed further horizontally into the folding process
Data Source
Figure 1~4
Figure 5~6
Figure 7
AI summary
The invention relates to a method for producing an electrode stack (20) for an energy storage device of a motor vehicle, wherein cathodes (6) and anodes (4) are alternately stacked on top of each other with an intermediate separator strip (2), wherein the separator strip (2) is first covered with the cathodes (6) and anodes (4) so that an electrode strip (1) is formed, wherein the electrode strip (1) is then folded several times to stack the cathodes (6) and anodes (4) on top of each other, and wherein the electrode strip (1) is aligned in a horizontal plane for folding and is folded section by section or completely between the electrodes.It is provided that the electrode strip (1) is conveyed towards a holder (25) and is gradually folded into the holder (25), and that at least two opposing grippers (12) are guided along a curved track (30) which is oriented at least substantially perpendicular to the extent of the electrode strip (1) or the track (8) in such a way that they gradually grip the electrode strip (1) between every second electrode (4,6) and fold it into the holder (25) by the curved movement.