Battery Monocell Thermal Cutting for Self-Insulated Edges

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Solution Overview

Problem

The production of lithium-ion battery monocells is costly and inefficient due to complex stacking processes, leading to high reject rates and increased costs as process speed demands rise.

Innovation Solution

A method involving the use of plastic substrates with metal coatings for current conductors in the anode and cathode films, where thermal cutting vaporizes the metal coatings and melts the plastic substrates to insulate cut edges, simplifying the production process and preventing short circuits, and an auxiliary joining material can be applied for further insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If complex stacking processes are used for producing monocells, then manufacturing precision can be maintained, but productivity decreases and production costs increase

Engineering Contradiction:

Improvemonocell production speedVSAvoidstacking process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple individual stacking operations into a single integrated lamination process. Multiple electrodes and separators are laminated together in one continuous operation to form a complete cell stack, eliminating the need for sequential stacking steps and significantly improving productivity while reducing process complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies adhesive tapes to electrodes and separators in advance before the lamination process. This preliminary action ensures proper positioning and bonding readiness, allowing the entire stack to be assembled in one rapid lamination step rather than requiring precise alignment during stacking

Inventive Principle:

Principle #10Preliminary action

2Productivity

If process speed is increased in monocell production, then productivity improves, but manufacturing precision deteriorates and reject rates increase

Engineering Contradiction:

Improvemonocell production speedVSAvoidposition tolerance

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Adhesive tapes are applied to electrodes and separators beforehand with pre-determined positioning. This preliminary action establishes fixed reference points that guide the lamination process, ensuring consistent position tolerances even at high production speeds

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces precise mechanical stacking operations with a thermal lamination process. The lamination unit applies heat and pressure to bond components together, eliminating the need for mechanical alignment and positioning systems that become problematic at high speeds

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If thermal cutting is used to singulate monocells, then productivity increases, but electrical short circuits may occur at cut edges

Engineering Contradiction:

Improvesingulation speedVSAvoidelectrical insulation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent converts the potentially harmful effect of thermal cutting (which could damage insulation) into a beneficial process. The controlled thermal cutting simultaneously vaporizes metal coatings and melts plastic substrates to create self-insulating cut edges, eliminating the need for separate insulation steps while maintaining electrical reliability

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The thermal cutting process utilizes phase transitions of materials - metal coating vaporization and plastic substrate melting - to create electrically insulating surfaces at cut edges. The melted plastic flows to cover and insulate the conductive surfaces, preventing short circuits

Inventive Principle:

Principle #36Phase transitions

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 method enables fast, economical, and reliable production of monocells with reduced risk of electrical short circuits and defects, minimizing reject rates and lowering production costs.

Implementation Method 1

cutting the film layer arrangement by means of a thermal cutting method, wherein the metal coating on the plastic substrate vaporizes

Methodology Applied

Scientific EffectVaporization: Evaporation

Implementation Method 2

the plastic substrate melts partially and spreads over the cut surface of the first anode layer or of the first cathode layer and electrically insulates the same

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20230387470A1Galvanic monocell and method for producing the same

Publication Date: 2023.11.30 POWERCO SE

AI summary

A monocell and a method for producing a monocell for a battery cell. In this method, a first separator film, an anode film, a second separator film, and a cathode film are stacked in this sequence to form a film layer arrangement and fed to a thermal cutting process. The cutting of the film layer arrangement is accomplished by a thermal cutting method, wherein a first metal coating on the anode film and a second metal coating on the cathode film vaporize in the cut region. The plastic substrate of the anode melts partially and spreads over the cut surface of the first anode layer and electrically insulates the same. The plastic substrate of the cathode melts partially and spreads over the cut surface of the first cathode layer and electrically insulates the same.