Separator Roll Assembly with Flexible Buffer for Shock Absorption

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Solution Overview

Problem

Conventional lithium-ion secondary battery assemblies are prone to deformation and foreign matter generation due to external forces during transport, as the gap between separator rolls is not adequately protected, leading to potential unusability of the separator rolls.

Innovation Solution

A method involving a pillar-shaped core member and flexible buffer members with axis holes, alternately arranged between rolls, to absorb external forces and prevent contact-induced damage, using materials like sponge or urethane foam for the buffer members.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If separator rolls are arranged with larger gaps to accommodate assembly errors, then assembly ease is improved, but reliability deteriorates due to increased risk of contact and deformation under external force

Engineering Contradiction:

Improveassembly easeVSAvoidprotection from external force

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A buffer member made of flexible material is inserted between adjacent separator rolls to act as an intermediary element. This buffer member prevents direct contact between separator rolls while accommodating assembly variations, thus maintaining both assembly ease and protection against external forces during transport

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The buffer member is pre-installed between separator rolls before transport to provide beforehand cushioning. This cushioning effect absorbs external forces and shocks that may occur during transport, preventing deformation of separator rolls while allowing sufficient gap for assembly tolerance

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If firm material is used for spacer to reduce gap between separator rolls, then reliability is improved, but harmful factors worsen due to friction and foreign matter generation

Engineering Contradiction:

Improvegap controlVSAvoidforeign matter generation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The material parameter of the buffer member is changed from firm material to flexible material. This parameter change reduces friction between the buffer member and separator rolls, preventing foreign matter generation while still maintaining adequate gap control and protection against external forces

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The buffer member is made of flexible material that can deform to accommodate separator rolls while maintaining contact. This flexibility reduces friction and prevents foreign matter generation compared to firm materials, while still providing adequate gap control and protection

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If firm material is used for spacer to provide structural support, then strength is improved, but harmful factors worsen due to rubbing and foreign matter generation

Engineering Contradiction:

Improvestructural supportVSAvoidrubbing damage

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The material parameter is changed from firm to flexible, which reduces the coefficient of friction between the buffer member and separator rolls. This parameter change eliminates rubbing damage and foreign matter generation while the buffer member still provides adequate structural support through its flexible nature

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The buffer member is designed as a simple flexible component that can be easily replaced if needed. While it provides structural support, its primary function is to prevent rubbing damage through its flexible material properties, accepting that it may wear but preventing damage to the more critical separator rolls

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

The assembly effectively protects the film from external forces during transport by absorbing shocks and preventing roll-to-roll contact, thereby maintaining the integrity of the separator rolls and preventing foreign matter generation.

Implementation Method 1

at least one first buffer member made of a flexible material and having an axis hole

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

absorbing shocks and preventing roll-to-roll contact

Methodology Applied

Scientific EffectShock absorption: Damping

Data Source

PatentUS10431794B2Method for producing assembly, and assembly

Publication Date: 2019.10.01 SUMITOMO CHEM CO LTD

AI summary

To provide (i) a method for producing an assembly capable of protecting a film from external force during, for example, transport and (ii) such an assembly, a method for producing an assembly includes a step of inserting a pillar-shaped core member through a plurality of separator rolls and a buffer member(s) made of a flexibility material and provided between separator rolls such that the separator rolls and the buffer member(s) are arranged alternately.