Single-Direction Separator Folding for Battery Stack Assembly
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Solution Overview
Problem
Existing methods for manufacturing electric energy storage devices with a stack of electrodes separated by a continuous strip are costly and have low productivity due to the use of adhesive means and 'z-folding' systems, which reduce ionic transfer and increase production costs.
Innovation Solution
An apparatus and method that assemble a stack of electrodes by folding a continuous dielectric separator strip in a single direction without the need for adhesive means, using a winding device that overturns the strip around the electrodes to form a stable and precise stack, reducing costs and improving performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive means are used to join electrodes to the separator, then the electrodes are securely positioned, but the manufacturing cost increases and ionic transfer is reduced
Solution Approach 1:
The patent removes the adhesive layer from the electrode-separator assembly, extracting the harmful element that blocked ionic transfer. The separator directly contacts the electrodes without adhesive intermediaries, eliminating the cost and performance penalty while maintaining structural integrity through the folding geometry itself.
Solution Approach 2:
The patent introduces a novel intermediary structure - the folded separator edges that interlock with electrode edges. This geometric intermediary replaces the chemical intermediary (adhesive) and enables both secure positioning and ionic transfer by maintaining direct contact between separator and electrode surfaces.
2Reliability
If adhesive means are used to join electrodes to the separator, then the electrodes are securely positioned, but the ionic transfer between electrochemical cells is reduced
Solution Approach 1:
The patent removes the adhesive layer that was blocking ionic pathways. By extracting this harmful element, the separator edges can directly contact electrode edges, creating continuous ionic channels without the resistance introduced by adhesive materials.
Solution Approach 2:
The patent utilizes the inherently porous structure of the separator material at its edges to facilitate ionic transfer. The folded edges maintain direct contact with electrode edges through physical interlocking, allowing ions to pass through the porous separator structure without encountering adhesive barriers.
3Shape
If a z-folding system is used to assemble the electrode stack, then the electrodes are arranged in alternating sequence, but the productivity is reduced
Solution Approach 1:
The patent inverts the conventional z-folding approach by using single-direction folding. Instead of alternating fold directions that require complex apparatus movements, the separator is folded consistently in one direction, simplifying the apparatus design and enabling faster, more continuous manufacturing while still achieving the alternating electrode arrangement.
Solution Approach 2:
The patent introduces dynamic elements to the folding apparatus, including movable folding lines and adjustable rollers, that allow the single-direction folding process to adapt to different electrode configurations and maintain high productivity. The system can dynamically adjust folding parameters without changing the fundamental single-direction approach.
Data Source
AI summary
Production apparatus and method for producing devices for storing electric energy are disclosed, wherein stacks of flat cathodes and anodes that face one another alternately with the interposition of a separator are produced, and in which the separator is formed by a single continuous strip folded several times in a single folding direction.