Separator Zigzag Folding Buffer Roller Tension Control
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Solution Overview
Problem
The existing secondary battery manufacturing methods using zigzag stack type devices face challenges in maintaining position accuracy and yield due to variations in separator dimensions, leading to potential fluttering and reduced accuracy of the electrode plate group.
Innovation Solution
The method involves using buffer rollers to maintain a tension-free state during zigzag folding, allowing continuous folding without pre-cutting the separator, and employing ionized air to prevent static electrification, which enables smooth pulling and folding of the separator, thereby improving accuracy and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the separator is suspended in a tension-free state between guide members during zigzag folding, then the position accuracy of the separator and electrode plates is improved, but the separator may flutter and be drawn into the guide members, reducing manufacturing precision
Solution Approach 1:
A buffer roller is introduced as an intermediary element between the separator and the support structure. The buffer roller applies a controlled buffering force to the separator during zigzag folding, preventing it from fluttering and being drawn into guide members while maintaining the tension-free suspension state that ensures position accuracy.
Solution Approach 2:
The buffering force applied by the buffer roller is dynamically adjusted based on the folding process. By changing the magnitude of the buffering force according to the separator's position and state during zigzag folding, the system maintains both the tension-free condition for accuracy and sufficient stability to prevent fluttering.
2Manufacturing precision
If the separator is cut to a specific length before zigzag folding, then the tension-free state and position accuracy are maintained, but the separator yield decreases due to margin parts required for cutting
Solution Approach 1:
The separator is supplied continuously without cutting during the zigzag folding process. The buffer roller maintains the tension-free state and position accuracy throughout the continuous folding operation, eliminating the need for margin parts and cutting operations, thereby maximizing separator yield.
Solution Approach 2:
The buffer roller is positioned and configured in advance to provide the necessary buffering force before the separator enters the folding zone. This preliminary positioning ensures that the separator maintains its tension-free state throughout the entire folding process without requiring post-cutting adjustments or margin parts.
3Manufacturing precision
If multiple guide members are used to fold the separator zigzag, then the folding accuracy is improved, but the device complexity and number of components increase
Solution Approach 1:
The buffering function is extracted from the guide members and assigned to a dedicated buffer roller. This separation of functions allows the guide members to focus solely on guiding and folding the separator with high accuracy, while the buffer roller handles the stabilization and flutter prevention, thereby reducing the functional burden and potential complexity of the guide member system.
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 approach ensures accurate and efficient zigzag folding of separators with varying dimensions, maintaining product quality and increasing separator yield by preventing fluttering and static attraction, while simplifying the apparatus and reducing the number of guide members required.
Implementation Method 1
a buffer roller which makes contact with one surface of the separator, and is movable vertically; the buffer roller being located at a predetermined upward position or downward position while contacting the separator, during zigzag folding by movement of the guide members, the buffer roller moves downward or upward
Implementation Method 2
employing ionized air to prevent static electrification
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
The purpose of the present invention is to enable smooth pulling of a separator by guide members by inhibiting a phenomenon in which, when the separator is being pulled by the guide members, the separator moves in the width direction and rattles. The present invention is provided with: a step in which a separator (4) is zigzaggedly folded by being pulled by guide members (21); and a step in which, while buffer rollers (45, 46), which are disposed between support rollers (42, 43, 44) for supporting the separator (4) at midpoints located at an upstream side of a suspension roller (41) in the conveyance direction, said buffer rollers being formed so as to be capable of coming into contact with an upper surface of the separator (4) and ascending or descending to adjust the positions thereof in the vertical direction, are in a state of being stationed in a prescribed downward position, the separator (4) is suspended from the suspension roller (41) and between the guide members (21), and when the separator is being zigzaggedly folded in accordance with the movement of the guide members (21), the buffer rollers (45, 46) ascend to feed an amount of length of the separator (4), said amount being proportional to that drawin by the guide members (21).