Meandering Induction Heating Plate for Uniform Electrode Assembly Bonding
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Solution Overview
Problem
The existing methods for manufacturing electrode assemblies face challenges in achieving uniform temperature distribution during the bonding process, leading to inconsistent adhesive forces between electrodes and separators, which affects the performance and efficiency of the electrode assembly.
Innovation Solution
An induction heating device with a meandering serpentine patterned coil is used to uniformly heat the electrode assembly, ensuring consistent temperature distribution across the stack, thereby improving the bonding process and reducing temperature non-uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat and pressure are applied to the stack to bond electrodes and separator, then bonding strength is improved, but temperature uniformity deteriorates due to differences in stacked positions
Solution Approach 1:
The induction heating coil is divided into multiple independent heating zones along the stacking direction, with each zone capable of being controlled separately. This segmentation allows different temperature levels to be applied to different stacked positions, compensating for the temperature non-uniformity caused by varying stack heights and ensuring uniform bonding across the entire electrode assembly.
Solution Approach 2:
Different regions of the stack receive different heating intensities based on their specific requirements. The induction heating coil is designed to provide localized heating at different stacked positions, with higher power input for regions that require more heat and lower power input for regions that require less heat, thereby achieving uniform temperature distribution and consistent adhesive force throughout the assembly.
2Device complexity
If conventional coil shape is used for induction heating, then device simplicity is maintained, but temperature uniformity deteriorates
Solution Approach 1:
The induction heating coil is divided into multiple independent heating zones along the stacking direction, with each zone capable of being controlled separately. This segmentation allows different temperature levels to be applied to different stacked positions, compensating for the temperature non-uniformity caused by varying stack heights and ensuring uniform bonding across the entire electrode assembly.
Solution Approach 2:
The heating coil is designed with multi-dimensional spatial arrangement, extending in both horizontal and vertical directions to create a three-dimensional heating field. This dimensional expansion allows the heating system to address temperature non-uniformity in multiple directions simultaneously, achieving comprehensive and uniform heating of the electrode stack.
3Manufacturing precision
If heat and pressure are applied for extended period to ensure uniform bonding, then adhesive force uniformity is improved, but manufacturing time increases
Solution Approach 1:
The induction heating system employs periodic heating cycles with varying power levels for different heating zones. By applying heat in controlled periodic pulses rather than continuous heating, the system achieves uniform bonding more quickly while preventing overheating and reducing total processing time.
Solution Approach 2:
The heating parameters (power, temperature, time) are dynamically adjusted for different zones and stages of the bonding process. By optimizing these parameters based on real-time feedback and pre-programmed sequences, the system achieves uniform adhesive force with significantly reduced bonding time compared to conventional constant-parameter heating methods.
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 solution enables faster and more uniform manufacturing of electrode assemblies with reduced air permeability deviations, resulting in enhanced performance and efficiency by ensuring consistent adhesive forces across the assembly.
Implementation Method 1
a method of inductively heating a stack including an electrode and a separator has been considered
Implementation Method 2
an induction heating device including at least one induction heating plate and an induction heating coil built in the induction heating plate
Data Source
AI summary
An induction heating device, a method for manufacturing an electrode assembly including the same, and an apparatus for manufacturing an electrode assembly including the same are all provided. The induction heating device includes an induction heating plate with an induction heating coil included therein. The inducting heating coil includes a first part defining a meandering serpentine pattern along a longitudinal direction of the induction heating plate, and a second part configured to cross the first part of the induction heating coil when projected on a plane from a top view. The second part includes segments extending in the longitudinal direction along opposing sides of the first part in the width direction of the induction heating plate.