Semi-Automatic Li-Ion Battery Assembly with Continuous Separator
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Solution Overview
Problem
Current methods for manufacturing lithium-ion electrochemical accumulators, such as winding and stacking, face challenges with flexible electrodes, brittle electrolytic separators, and manual handling risks, leading to inefficiencies and potential short circuits.
Innovation Solution
A method involving automatic winding of a continuous electrolytic separator strip with manual positioning of electrodes to form a stack, using two-sided and one-sided electrodes with the same polarity, allowing for motor-driven or hand-driven assembly without prior manual stacking, and maintaining separator tension to prevent perforation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If winding method is used, then equipment complexity is reduced, but electrode flexibility requirement increases causing manufacturing limitations
Solution Approach 1:
The invention divides the manufacturing process into two distinct phases: a preliminary stacking phase where electrodes are assembled in flat configuration, and a subsequent winding phase where the stacked assembly is wound into the final cylindrical form. This segmentation allows each phase to use equipment suited for its specific requirements, resolving the contradiction between equipment simplicity and electrode flexibility constraints.
2Ease of manufacture
If entirely manual stacking method is used, then electrode assembly is possible, but productivity is reduced due to long positioning steps
Solution Approach 1:
The invention performs preliminary stacking of electrodes in a flat, accessible configuration before winding. During this preliminary phase, all electrode positioning and alignment is completed while the assembly is still flat and easily accessible. This preliminary action eliminates the need for complex positioning operations during the winding phase, thereby maintaining ease of manufacture while significantly improving productivity.
3Productivity
If entirely automated winding method is used, then productivity is improved, but manual handling of brittle separator is required causing short circuit risk
Solution Approach 1:
The electrolytic separator is pre-assembled with the electrodes during the preliminary stacking phase, creating a complete flat assembly before winding begins. This preliminary action ensures the separator is properly positioned and protected before any automated winding occurs, eliminating the need for manual separator handling during high-speed automated winding operations and thereby maintaining both productivity and reliability.
4Ease of operation
If preliminary stacking of electrodes is performed manually, then winding can proceed, but separator handling complexity increases
Solution Approach 1:
The invention merges the separator assembly operation with the electrode stacking operation into a single integrated process. The separator is assembled simultaneously with the electrodes during the preliminary stacking phase, rather than as a separate subsequent step. This merging eliminates the need for complex dedicated separator handling equipment and procedures, simplifying both the operation and device complexity.
Data Source
AI summary
A semi-automatic method for making a Li-ion electrochemical accumulator according to which a continuous electrolytic separator strip is automatically wound on two-sided electrodes manually and alternately stacked according to their polarity. By the method, it is not necessary to assemble or manually cut out each electrolytic separator inserted between two adjacent electrodes in the stack and of opposite polarity.