Jellyroll Electrode Tab Forming to Prevent Buckling

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Solution Overview

Problem

The conventional bending and forming processing of non-coated portions in jelly roll-type electrode assemblies require multiple complex steps and facilities, leading to increased processing cycles and facility sizes, and are prone to buckling due to frictional forces.

Innovation Solution

A tab forming device and method that uses a single forming jig to bend and flatten the electrode tab in a radial direction without rotation, simplifying the processing steps and reducing the risk of buckling by using a pre-forming perimeter surface and a bend inducing surface designed to guide the tab into a radially inward position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple processing steps and facilities are used for bending and flattening the non-coated portion, then the tab forming is more thorough, but the processing cycle increases and facility complexity increases

Engineering Contradiction:

Improvetab forming qualityVSAvoidfacility complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple processing functions (bending and flattening) into a single integrated forming facility. The forming jig incorporates both the bending mechanism and flattening mechanism, allowing both operations to be performed simultaneously or sequentially in one step, thereby reducing facility complexity while maintaining tab forming quality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The forming jig is designed as a multi-functional device that can perform both bending and flattening operations. The jig includes a bending unit with rotation capability and a flattening unit with pressing capability, making a single device capable of accomplishing what previously required multiple specialized facilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Force

If the non-coated portion is pressed without rotating the jig, then the pressing force is applied directly, but buckling occurs due to frictional force

Engineering Contradiction:

Improvepressing forceVSAvoidbuckling prevention

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The forming jig incorporates rotation capability that allows it to dynamically adjust during the pressing operation. By rotating the jig during pressing, the frictional force between the jig and the non-coated portion is reduced, preventing buckling while still applying sufficient pressing force to achieve the desired flattening.

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If the end portion of the non-coated portion is not collected in the radial direction before pressing, then the pressing operation is simpler, but buckling and collapse occur

Engineering Contradiction:

Improvepressing operation simplicityVSAvoidcollapse prevention

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The forming jig incorporates a bending unit that performs preliminary bending of the non-coated portion in the radial direction before the flattening pressing operation. This preliminary action collects and positions the end portion of the non-coated portion, preventing buckling and collapse during subsequent pressing while maintaining operational simplicity.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If conventional multi-step processing is used, then each step can be optimized independently, but the processing cycle cannot be decreased

Engineering Contradiction:

Improveprocessing optimizationVSAvoidprocessing cycle

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent merges the bending and flattening processing steps into a single integrated operation using one forming facility. This eliminates the need for separate processing steps and facilities, thereby decreasing the processing cycle and improving productivity while maintaining the ability to optimize each function within the integrated system.

Inventive Principle:

Principle #5Merging (Combining)

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 proposed solution significantly reduces the number of processing steps, minimizes the complexity of facilities, and decreases the likelihood of buckling, thereby improving productivity and facilitating a more efficient tab forming process.

Implementation Method 1

a forming jig bending the electrode tab, wherein the forming jig has a pre-forming perimeter surface and a bend inducing surface

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

a flattening jig flattening the bent electrode tab further

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS20250030058A1Tab forming device of jellyroll-type electrode assembly and forming method using the same

Publication Date: 2025.01.23 LG ENERGY SOLUTION LTD

AI summary

A forming device and a forming method thereof bends an electrode tab portion that is exposed to the end portion of a jelly roll-type electrode assembly in the axial direction thereof, in a radial direction. The forming device may include a forming jig bending the electrode tab, and a flattening jig flattening the bent electrode tab further. The forming jig comprises a pre-forming perimeter surface and a bend inducing surface. The pre-forming perimeter surface has an inner radius that increases from a base end toward a leading end elongated in a pressing direction. The bend inducing surface connects to the base end of the pre-forming perimeter surface, and extends inwards, in the radial direction.