Continuous Prismatic Cell Stacking Rotary Disc System
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Solution Overview
Problem
Current methods for manufacturing large format lithium ion batteries face challenges in precision, efficiency, and safety due to manual hand stacking and the need for separate machines to cut and handle thin electrode and separator layers, which are prone to static electrical charges and thermal management issues.
Innovation Solution
A continuous prismatic cell stacking system utilizing a rotary disc to successively stack separator, cathode, and anode layers at high speed, with holders and clamps for precise positioning, cutters for variable size layers, and a rotary heating device for sealing, reducing the need for separate machines and minimizing contact with electrode and separator surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual hand stacking is used for large format cells, then flexibility in handling is maintained, but manufacturing precision and quality consistency deteriorate
Solution Approach 1:
The patent replaces manual mechanical stacking with an automated stacking machine that uses a picking device with vacuum suction to automatically pick up electrode layers and deposit them onto the cell stack. This substitution of manual operations with automated mechanical systems maintains handling efficiency while significantly improving stacking precision and quality consistency.
2Ease of operation
If separate machines are used to cut and handle electrode layers, then handling flexibility is maintained, but device complexity and manufacturing time increase
Solution Approach 1:
The patent combines multiple separate functions (cutting, folding, picking, and stacking) into a single integrated stacking machine. The machine includes a cutting device, a folding device, and a picking device all integrated into one system, eliminating the need for separate machines for each operation and reducing overall device complexity while maintaining operational flexibility.
Solution Approach 2:
The stacking machine is designed as a multi-functional device that can perform cutting, folding, picking, and stacking operations in sequence. The picking device can handle both cathode and anode electrode layers with the same vacuum suction mechanism, demonstrating universal functionality that reduces the number of specialized machines needed.
3Manufacturing precision
If vacuum picking is used to hold electrode layers, then handling precision is improved, but handling time increases
Solution Approach 1:
The patent implements a continuous stacking process where the picking device operates in a continuous cycle of picking up electrode layers and depositing them onto the stack. The automated system maintains continuous motion without interruption, eliminating the time losses associated with manual repositioning and setup, while the vacuum suction ensures precise positioning throughout the continuous operation.
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 system enables rapid, precise, and efficient production of large format prismatic cells with improved stability and reduced capital investment, capable of handling high energy demands like electric vehicles, while maintaining quality and reducing static issues.
Implementation Method 1
engaging a rotary heating device located at the side of rotary disc that can heat and seal the separator layers
Implementation Method 2
The electrode is held onto the pick-up device via a reduced air pressure (vacuum) applied at the point of contact of the device and the electrode surface
Data Source
AI summary
A continuous prismatic cell stacking system and method is disclosed. The system comprises: (a) devices on the system to supply a separator layer, a cathode layer, and an anode layer; and (b) one cutter on the frame for cathode layer and anode layer; and (c) conveyer system to convey the stacked cell. The conveyer system comprises a rotary disc and a transfer belt. The said rotary disc is round shape, or multi-equilateral shape, or track & field shape.