Polymer Thread Joining Separator Webs Battery Element
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Solution Overview
Problem
Current methods for joining battery elements in electric vehicles lack efficiency and material cost-effectiveness, particularly in forming strong connections between separator webs without affecting electrode materials.
Innovation Solution
A method involving the application of a polymer thread beyond its softening temperature between two separator webs, forming a material bond connection as the thread cools, allowing for encapsulation of electrode materials and enabling the production of thin, cost-effective battery elements with short cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polymer thread is heated beyond softening temperature to form material bond connection, then joining strength is improved, but risk of affecting electrode material increases
Solution Approach 1:
The heating process is spatially segmented into a localized heating zone that only affects the polymer thread, while the electrode material remains in a separate, unheated region. This segmentation allows the polymer to reach softening temperature for bonding without exposing the electrode material to harmful temperatures.
Solution Approach 2:
The heating is applied locally only to the polymer thread in the joining zone, creating a localized high-temperature region. The electrode material, being outside this localized zone, maintains its original temperature and properties. This local quality approach enables strong bonding without widespread thermal damage.
2Reliability
If traditional joining methods are used, then electrode material is protected, but productivity is reduced
Solution Approach 1:
The patent replaces traditional mechanical or chemical joining methods with a thermal field-based polymer bonding system. This substitution enables faster processing speeds and higher productivity while maintaining electrode material protection through controlled localized heating.
Solution Approach 2:
The patent changes the temperature parameter locally in the joining zone, heating the polymer thread above its softening temperature only where needed for bonding. This parameter change enables rapid bonding suitable for high-speed production while the electrode material, being outside the heated zone, remains at safe temperatures.
3Stability of the object's composition
If thicker separator webs are used, then structural stability is improved, but battery element thickness increases
Solution Approach 1:
The patent uses composite construction where thin separator webs are bonded together through softened polymer threads. The polymer acts as an adhesive matrix that binds the thin separator layers, creating a composite structure that achieves the required structural stability without increasing the overall thickness of the battery element.
Solution Approach 2:
The polymer thread undergoes a phase transition from solid to softened state during heating, enabling it to flow and penetrate between thin separator webs. Upon cooling, it solidifies to form strong bonds. This phase transition mechanism allows effective joining of thin separators without requiring thick individual separator layers.
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 achieves a strong, adhesive material bond between separator webs without affecting the electrode material, enabling the production of thin, cost-effective battery elements with extremely short cycle times, suitable for various vehicle types including electric vehicles.
Implementation Method 1
heating said at least one polymer thread within a heating zone beyond a softening temperature
Implementation Method 2
When the at least one polymer thread is heated, it is heated above its softening temperature, so that when the connection between the first separator web and the second separator web is formed, a plastic deformation occurs
Implementation Method 3
cooling of the at least one polymer thread between the separator webs and forming at least one material bond (material locking) connection between them
Data Source
AI summary
A process for joining a battery element (49) by at least one polymer thread (28, 30), comprises the method steps:a) applying a web-shaped or sheet-shaped electrode material (16) to a first separator web (12),b) heating the at least one polymer thread (28, 30) above the softening temperature of the polymer material,c) introducing at least one polymer thread (28, 30) between the first separator web (12) and a further second separator web (40) to be applied to the first separator web (12), andd) cooling the at least one polymer thread (28, 30) between the separator webs (12, 40) and forming at least one material-bond compound (46, 48) therebetween.