Lithium-Sulphur Cell Zigzag Laminate for Automated Manufacturing
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Solution Overview
Problem
The existing batch processes for manufacturing lithium-sulphur cells are time-consuming and complex, making automation difficult due to the need for precise cutting of electrodes and separate components, which complicates the assembly and manufacturing process.
Innovation Solution
A lithium-sulphur cell is assembled using a laminate configuration where the cathode and anode are offset relative to each other in a zigzag fold, allowing for continuous web formation and automated manufacturing without the need for pre-cutting, with the cathode accessible from one side and the anode from the other, facilitating efficient and streamlined production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual sheets of cathode, separator and anode are pre-cut and assembled in a batch process, then the cell structure is formed, but the manufacturing process becomes complex and difficult to automate
Solution Approach 1:
The patent merges the cathode, separator, and anode into a single continuous laminate structure that is folded into a zigzag configuration. This integration eliminates the need for separate handling and assembly of individual pre-cut sheets, thereby simplifying the manufacturing process and enabling automation while maintaining proper cell structure formation.
Solution Approach 2:
The patent transitions from a planar assembly of separate sheets to a three-dimensional zigzag folded laminate. This dimensional transformation allows the continuous laminate to provide both structural integrity and proper electrode spacing, enabling automated manufacturing while achieving the desired cell configuration without complex cutting and assembly operations.
2Ease of operation
If sheets are cut to provide protruding tabs for contact leads, then electrical connection is enabled, but the process complexity increases
Solution Approach 1:
The patent uses the zigzag folding of the continuous laminate to create accessible electrode regions at the ends of the folded structure. This three-dimensional configuration naturally provides protruding portions for contact lead connection without requiring any cutting operations, thereby eliminating cutting process complexity while maintaining ease of electrical connection.
Solution Approach 2:
The patent extracts the need for cutting operations entirely from the manufacturing process. By designing the continuous laminate to be folded into a zigzag configuration, the accessible electrode regions are created through folding geometry rather than material removal, eliminating the complex cutting step while preserving electrode accessibility for contact lead attachment.
3Productivity
If a continuous laminate is used instead of pre-cut sheets, then automated manufacturing is enabled, but electrode accessibility must be maintained
Solution Approach 1:
The patent folds the continuous laminate into a zigzag configuration, transforming it from a flat two-dimensional sheet into a three-dimensional structure. This folding creates accessible electrode regions at the ends of the zigzag folds, maintaining ease of electrode access for contact lead connection while enabling continuous automated manufacturing of the entire cell structure.
Solution Approach 2:
The patent combines the functions of continuous laminate formation and electrode accessibility into a single zigzag folded structure. The continuous nature of the laminate enables automated manufacturing, while the zigzag folding geometry simultaneously provides the necessary electrode access points, merging productivity and operability into one integrated design.
Data Source
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AI summary
A lithium-sulphur electrochemical cell comprising a laminate comprising: a lithium anode comprising a layer of lithium metal foil or lithium metal alloy foil; a cathode comprising an active sulphur material; a porous separator disposed between the lithium anode and the cathode;and an electrolyte; wherein: the laminate is folded in a zigzag configuration; and the cathode is offset relative to the lithium anode in the laminate, such that the cathode is accessible from one side of the laminate and the lithium anode is accessible from an opposite side of the laminate.