Pouch Cell Electrode Layout for Roll-to-Roll Lamination Alignment

Solution Overview

Problem

The manufacturing of battery cells with dissimilar-sized electrodes poses challenges in alignment and stacking due to the need for complex dimension detection technologies, leading to inefficiencies in the continuous roll-to-roll lamination process.

Innovation Solution

The design includes a cathode and anode with current collectors of the same dimensions in the X-axis and/or Y-axis, allowing for easy mechanical positioning and alignment, enabling continuous roll-to-roll lamination and improved stacking speed by ensuring similar edges for easier mechanical manipulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If dissimilar-sized electrodes are used in battery cells, then the cell design can optimize electrochemical performance, but the manufacturing process becomes complex requiring dimension detection technologies and reduced stacking speed

Engineering Contradiction:

Improvestacking speedVSAvoidalignment system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies homogeneity by making the separator and current collectors have uniform dimensions (same length and width) across different electrodes. This standardization allows all components to be aligned using simple mechanical positioning systems without requiring complex dimension detection, thereby maintaining high stacking speed while simplifying the alignment system.

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The patent changes the dimensional parameters of the separator and current collectors to be equal in length and width. This parameter standardization enables the mechanical positioning system to align all electrodes uniformly, eliminating the need for complex detection technologies and achieving rapid stacking at speeds exceeding 5 times conventional methods.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If dissimilar-sized electrodes are used in battery cells, then the cell design can optimize electrochemical performance, but the manufacturing process requires complex dimension detection technologies

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoiddimension detection complexity

Core Design Contradiction:

ProductivityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent applies homogeneity by making the separator and current collectors have uniform dimensions (same length and width) across different electrodes. This standardization allows all components to be aligned using simple mechanical positioning systems without requiring complex dimension detection, thereby maintaining high stacking speed while simplifying the alignment system.

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The patent replaces complex optical or sensor-based dimension detection systems with a simple mechanical positioning system. By standardizing component dimensions, the manufacturing process uses straightforward mechanical alignment methods instead of sophisticated detection technologies, improving manufacturing efficiency while reducing system complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of time

If dissimilar-sized electrodes are used in battery cells, then the cell design can optimize electrochemical performance, but the stacking process time increases from 0.6 seconds per electrode to slower speeds

Engineering Contradiction:

Improvetime per electrodeVSAvoidalignment process simplicity

Core Design Contradiction:

Loss of timeVSEase of manufacture

Solution Approach 1:

The patent applies homogeneity by making the separator and current collectors have uniform dimensions (same length and width) across different electrodes. This standardization allows all components to be aligned using simple mechanical positioning systems without requiring complex dimension detection, thereby maintaining high stacking speed while simplifying the alignment system.

Inventive Principle:

Principle #33Homogeneity

Data Source

PatentUS20240405289A1Electrode design for continuous roll-to-roll lamination

Publication Date: 2024.12.05 OUR NEXT ENERGY INC

AI summary

A cell that includes a pouch, a cathode including a cathode current collector disposed between two cathode active material layers, an anode including an anode current collector disposed between two anode active material layers, and separator disposed between the cathode and the anode. A first dimension in an X-axis and/or Y-axis of the separator, anode current collector and cathode current collector are the same. A method of manufacturing the cell includes continuous roll to roll lamination of cell components.