Laminated Cell Resin Bonding for Separator Alignment
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Solution Overview
Problem
Conventional laminated cell manufacturing techniques face challenges in productivity and size reduction due to misalignment issues and the need for thermal fusion bonding, which increases the number of work steps and can lead to defects such as holes in the separator.
Innovation Solution
The method involves bonding resin members to surfaces of the electrodes and separators, facilitating alignment and integration, thereby reducing misalignment and allowing for smaller cell sizes through reduced thickness and fewer work steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal fusion bonding is used to bond the bag-shaped separator to the positive electrode, then the separator is securely bonded, but the thickness of the separator decreases and holes may form, requiring a larger interval between the electrode and bonding portion
Solution Approach 1:
A resin member is introduced as an intermediary component between the positive electrode and the separator. The resin member is bonded to the positive electrode, and the separator is then bonded to the resin member, eliminating the need for direct thermal fusion bonding between the separator and electrode. This prevents thickness reduction and hole formation in the separator while maintaining secure bonding.
2Manufacturing precision
If four portions of the bag-shaped separator are ally fused and bonded to position the positive electrode, then misalignment is prevented, but the number of work steps increases and productivity improvement becomes difficult
Solution Approach 1:
The positioning and bonding functions are merged into a single integrated process. The resin member serves as both the positioning element and the bonding medium, allowing the positive electrode to be positioned and secured in one step rather than requiring separate alignment and bonding operations at four different portions of the separator.
Solution Approach 2:
The resin member acts as an intermediary that simplifies the bonding process. Instead of directly bonding four portions of the separator to the electrode (requiring multiple precise operations), the resin member is first bonded to the electrode, providing a simplified interface for subsequent separator attachment, thereby reducing the number of work steps.
3Volume of moving object
If the bag-shaped separator is reduced in size to reduce cell size, then the cell becomes more compact, but misalignment risk increases and bonding reliability decreases
Solution Approach 1:
The resin member serves as a buffer and intermediary that maintains bonding reliability even when the overall cell size is reduced. It provides a stable bonding interface that is less sensitive to dimensional variations, allowing compact cell design without compromising the reliability of the electrode-separator connection.
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 enhances productivity by simplifying the stacking process, preventing short circuits, and enabling size reduction of the laminated cell while maintaining structural integrity.
Implementation Method 1
at least one of surfaces of the positive electrode or the negative electrode in a stacking direction has a portion to which a resin member is bonded
Data Source
AI summary
A laminated cell (100) of the present invention includes a laminated body (120) formed by sequential stacking a negative electrode (130), a separator (170, 180), a positive electrode (150), and a separator (170, 180). At least one of surfaces of the positive electrode (150) or the negative electrode (130) in a stacking direction (S) has a portion to which a resin member (190) is bonded. The separators each have a portion bonded to the resin member (190) on a side facing the at least one of surfaces. In the present invention, since the separators and at least one of the positive electrode and the negative electrode are integrated together, misalignment in a stacking work can be easily suppressed and the laminated cell has excellent productivity.