Lamination Roller Pressure Control for Separator-Safe Unit Cell Assembly
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Solution Overview
Problem
Conventional lamination devices cause damage to separator sheets due to constant pressure application, leading to increased defect rates in unit cells, especially when electrodes of varying thicknesses are laminated, and the thickness of the separator is reduced.
Innovation Solution
A lamination device with a vision unit that captures images of the unit cell in real time, allowing a control unit to adjust the pressure of the lamination roller based on brightness values to prevent damage to the separator and correct pressure imbalances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the lamination roller presses the electrode laminate with constant pressure to maintain stable operation, then the operational stability is improved, but the separator sheet may be damaged due to excessive impact especially when electrodes of varying thicknesses are laminated
Solution Approach 1:
The lamination roller's pressure is changed from constant to dynamically adjustable. The pressure adjusting unit modifies the pressing force in real-time based on electrode thickness variations, allowing the system to adapt to different electrode configurations while preventing separator damage through controlled pressure application.
Solution Approach 2:
The pressing pressure parameter is made variable rather than fixed. By adjusting the pressure parameter according to electrode thickness measurements or predetermined patterns, the system optimizes the lamination process to prevent separator damage while maintaining effective bonding.
2Productivity
If the transfer speed of the electrode laminate is increased to improve productivity, then the production efficiency is improved, but the impact on the separator sheet edge portion is further increased causing more damage
Solution Approach 1:
The lamination roller pressure is dynamically adjusted in response to transfer speed variations. At higher transfer speeds where impact is more severe, the pressure adjusting unit reduces the pressing force to compensate for the increased impact, thereby preventing separator damage while maintaining high productivity.
Solution Approach 2:
The system preemptively reduces pressure before high-impact conditions occur. By anticipating situations where high transfer speed will cause excessive impact on the separator, the pressure adjusting unit proactively lowers the pressing force to prevent damage before it occurs.
3Quantity of substance
If the thickness of the electrode in the electrode laminate is increased to improve battery capacity, then the energy density is improved, but the step difference between electrode and separator is increased causing more impact damage
Solution Approach 1:
The pressing pressure parameter is adjusted according to electrode thickness. For thicker electrodes that create larger step differences with the separator, the pressure adjusting unit increases the pressing force to ensure proper contact and bonding, while for thinner electrodes it reduces pressure to prevent damage from excessive force.
Solution Approach 2:
Different pressing forces are applied to different regions or conditions of the electrode laminate. The pressure adjusting unit tailors the local pressing characteristics to match the specific electrode thickness and step difference conditions, optimizing both bonding quality and damage prevention for each case.
4Adaptability or versatility
If the thickness of the separator sheet is reduced to improve battery design flexibility, then the design adaptability is improved, but the possibility of damage to the separator sheet is further increased when the same impact force is applied
Solution Approach 1:
The pressing pressure parameter is adjusted based on separator thickness. For thinner separators that are more susceptible to damage, the pressure adjusting unit reduces the pressing force to compensate for the reduced mechanical strength, thereby maintaining design flexibility while preventing separator damage during lamination.
Data Source
AI summary
The present invention discloses a lamination device and a unit cell manufacturing method. The lamination device of the present invention includes a vision unit disposed at a downstream side of the final cutter unit and configured to capture an image of the unit cell, and a control unit configured to calculate a brightness value of the captured image received from the vision unit and control the pressure adjusting unit to correct the pressure of the lamination roller unit according to the calculated brightness value.