Multilayer Electrode Manufacturing Apparatus with Integrated Foil Bonding
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Solution Overview
Problem
Conventional manufacturing of multilayer electrodes for lithium-ion capacitors requires separate processes for doping members and electrode stacking, leading to larger apparatus sizes, higher costs, and difficulties in accurately placing doping members within the stack structure.
Innovation Solution
An apparatus with suction portions and a control device that alternately sandwiches positive and negative electrodes between folded separator surfaces while bonding lithium metal foil to the electrodes, allowing for precise placement and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate processes are used for manufacturing doping members and stacking electrodes, then the doping member can be manufactured with sufficient lithium metal foil attachment, but the apparatus size becomes larger and manufacturing cost increases
Solution Approach 1:
The patent combines the doping member manufacturing process and the electrode stacking process into a single integrated apparatus. The doping member is manufactured and immediately stacked onto the electrode assembly within the same device, eliminating the need for separate manufacturing and stacking apparatuses. This merging of processes reduces overall apparatus size while maintaining the quality of doping member manufacturing through controlled lithium metal foil attachment and precise positioning mechanisms.
2Reliability
If separate processes are used for manufacturing doping members and stacking electrodes, then the doping member can be manufactured with sufficient lithium metal foil attachment, but the manufacturing cost becomes higher
Solution Approach 1:
The patent integrates doping member manufacturing and electrode stacking into one apparatus, eliminating the need for two separate production lines. This consolidation reduces capital equipment costs, lowers operational expenses through unified control systems, and decreases maintenance requirements. The single apparatus approach maintains high manufacturing quality while significantly reducing overall production costs compared to using separate dedicated apparatuses for each process.
3Shape
If the doping member is stacked after the stack structure is manufactured, then the stack structure can be formed with alternating positive and negative electrodes, but it is difficult to place the doping member at the predetermined location
Solution Approach 1:
The patent employs preliminary positioning mechanisms where the doping member is pre-positioned at the exact predetermined location on the electrode assembly before the stacking process begins. The apparatus includes positioning fixtures and alignment mechanisms that ensure the doping member is placed at the correct location (e.g., at specific intervals or at predetermined positions between electrodes) before the alternating positive and negative electrodes are stacked around it. This preliminary action ensures precise placement while maintaining the required stack structure formation.
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 the accurate placement of doping members within the stack structure, reducing manufacturing time and costs while minimizing apparatus size, thus improving the efficiency of multilayer electrode production.
Implementation Method 1
a first suction portion that has a suction surface for sucking and holding a sheetlike positive electrode
Data Source
AI summary
An apparatus includes a control device for a first suction portion, a second suction portion, and a folding portion so that each time a separator is folded, a positive electrode and a negative electrode are alternately sandwiched between folded surfaces of the separator. The control device controls the at least one of the first suction portion and the second suction portion so that doping foil is bonded to one of a current collector, the positive electrode, and the negative electrode sucked and held by the at least one of the first suction portion and the second suction portion. The control device controls the at least one of the first suction portion and the second suction portion so that the one of the current collector, the positive electrode, and the negative electrode having the lithium metal foil bonded thereto is transported and sandwiched between a predetermined pair of the folded surfaces of the separator.