Separator Tension Control for Battery Electrode Stacking

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Solution Overview

Problem

The existing methods for stacking secondary battery electrode plates face challenges with the reverse movement phenomenon and tension fluctuations, leading to deteriorated stacking quality and increased manufacturing time due to the lack of effective tension control during the stacking process.

Innovation Solution

A separator tension controlling apparatus and method that includes a separator moving member with adjustable lower feeding rollers and a length changing mechanism to maintain uniform tension, preventing reverse movement and allowing for faster stacking by reducing the weight of the moving member and eliminating the need for a dancer to control tension.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a separator reciprocating unit is used to continuously supply the separator by performing reciprocating movement, then the separator can be supplied continuously, but the separator path length changes according to the position of the separator reciprocating unit causing reverse movement phenomenon and tension fluctuations

Engineering Contradiction:

Improvecontinuous separator supplyVSAvoidseparator tension stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A dancer roller is introduced as an intermediary component between the separator supply system and the stacking system. The dancer roller acts as a mediator that absorbs path length changes and maintains constant separator tension, preventing reverse movement phenomenon while allowing continuous reciprocating motion for productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system dynamically adjusts the dancer roller position and tensioning force parameters to compensate for changing separator path lengths during reciprocating motion. By changing these parameters in real-time, the system maintains constant separator tension despite position variations, resolving the contradiction between continuous supply and tension stability.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If the separator path is reduced or increased according to the position of the separator reciprocating unit, then the separator can be supplied to different positions, but extra separator is generated and tension is not maintained constant

Engineering Contradiction:

Improveseparator position adjustmentVSAvoidseparator tension control

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The dancer roller serves as an intermediary that decouples the relationship between separator path length changes and tension variations. It allows the system to adapt separator position while maintaining constant tension through the mechanical feedback provided by the roller's rotation and position changes.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The dancer roller provides mechanical feedback about separator path length changes to the tensioning system. This feedback mechanism allows automatic adjustment of separator supply rate and tension to compensate for position changes, maintaining manufacturing precision while enabling adaptability.

Inventive Principle:

Principle #23Feedback

3Reliability

If a buffer roller is mounted to accommodate extra separator and maintain constant tension, then tension can be maintained, but the separator moves backward causing reverse movement phenomenon

Engineering Contradiction:

Improveconstant tension maintenanceVSAvoidseparator movement smoothness

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The dancer roller replaces the buffer roller as the intermediary component for tension maintenance. Unlike the buffer roller that causes reverse movement, the dancer roller maintains constant tension through controlled rotation and elastic deformation, providing smooth separator feeding without backward movement.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The dancer roller system is designed to be dynamic, allowing controlled movement and rotation in response to tension variations. This dynamic behavior enables the system to absorb path length changes smoothly without causing reverse movement, improving ease of operation while maintaining reliability.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20240178431A1Method and apparatus for controlling separator tension of laminated plates of secondary battery

Publication Date: 2024.05.30 MPLUS

AI summary

Proposed are a separator tension controlling apparatus and method for stacking an electrode plate of a secondary battery. The apparatus includes a separator loading member on which a fixing plate is mounted such that a separator loading unit, a separator supplying member, and a separator moving member which are mounted on an upper surface of a table are capable of being mounted so that a negative electrode and a positive electrode of the secondary battery are capable of being stacked to cross each other by a separator, the separator supplying member mounted on a first side of the separator loading unit such that the separator is capable of being supplied to the separator loading unit, and the separator moving member mounted on an upper side of the separator loading member such that the separator supplied from the separator supplying member is capable of being supplied with uniform tension.