Continuous Prismatic Cell Stacking System
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Solution Overview
Problem
Current methods for manufacturing large format lithium-ion battery cells are inefficient due to manual hand stacking, which leads to issues with maintaining concentricity, thermal management, and the need for extensive capital investment in machinery, especially for high-capacity applications like electric vehicles.
Innovation Solution
A continuous prismatic cell stacking system utilizing a conveyor belt, air suction pans, spools, positioning sensors, rollers, cutters, and glue guns to rapidly and accurately stack separator and electrode layers in a 'S-C-S-A-S' pattern, minimizing handling and contact with electrode surfaces, and stabilizing the stack for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual hand stacking is used for large format lithium-ion battery cells, then capital investment in machinery is reduced, but production efficiency is low and concentricity cannot be maintained
Solution Approach 1:
The stacking system is divided into multiple independent stacking stations (first stacking station, second stacking station, third stacking station) that can operate simultaneously. Each station handles specific layers (separator, cathode, anode), allowing parallel processing and significantly increasing production efficiency while maintaining manageable system complexity
Solution Approach 2:
The system implements continuous stacking operations where multiple cells are stacked simultaneously across different stations. The conveyor belt system enables continuous material flow and stacking operations without interruption, transforming discrete manual operations into a continuous automated process
2Productivity
If automated stacking machines are used, then production speed increases, but the complexity of the system and capital investment increase
Solution Approach 1:
The automated stacking system is segmented into multiple independent stations, each handling specific functions. This modular approach allows the system to achieve high productivity through parallel operations while keeping each individual station relatively simple and manageable
Solution Approach 2:
Each stacking station is designed to handle multiple layer types (separator, cathode, anode) using the same basic mechanism (rollers, cutters, positioning sensors). This multi-functionality reduces overall system complexity by using standardized components across different stations rather than requiring specialized equipment for each layer type
3Manufacturing precision
If electrode layers are handled and stacked sequentially, then positioning accuracy can be maintained, but production time increases
Solution Approach 1:
The stacking process is segmented across multiple stations, with each station dedicated to specific layer stacking. This allows simultaneous stacking operations for different cells at different stations, reducing total production time while maintaining positioning accuracy through dedicated positioning sensors at each station
Solution Approach 2:
The system performs preliminary positioning and alignment of electrode layers using positioning sensors before the actual stacking operation. This preliminary action ensures that when layers are stacked, they are already correctly positioned, maintaining manufacturing precision while enabling faster subsequent stacking operations
4Ease of operation
If separator layers are cut and folded automatically, then handling is minimized, but static charge accumulation occurs
Solution Approach 1:
The system replaces manual mechanical handling and folding operations with an automated cutting and stacking mechanism. The separator layers are cut to size and stacked directly without manual folding, minimizing handling while the automated process controls static charge accumulation through reduced contact and controlled movement
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 significantly reduces production time and capital investment, increasing efficiency by allowing multiple cells to be stacked simultaneously, from minutes to seconds, and requires fewer machines to meet high demand, enhancing manufacturing scalability and safety.
Implementation Method 1
engaging an air suction pan in each stacking location that holds the prismatic cell steady while it is being conveyed at high speed
Data Source
AI summary
A continuous prismatic cell stacking system and method are disclosed. The continuous prismatic cell stacking system, comprises: a frame; a conveyer belt; a plurality of air suction pans; at least three units for distributing separator including separator spool, positioning sensor of separator layer, upper roller of separator layer, lower roller of separator layer and cutter of separator layer; at least one unit for distributing cathode including cathode spool, positioning sensor of cathode layer, upper roller of cathode layer, lower roller of cathode layer, and cutter of cathode layer; and at least one unit for distributing anode including anode spool, positioning sensor of anode layer, upper roller of anode layer, lower roller of anode layer, and cutter of anode layer.