Battery Separator Winding with Pre-Bonded Break Regions
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Solution Overview
Problem
In lithium battery manufacturing, the misalignment of separator layers at the head and tail ends of the jelly roll during the winding process leads to poor battery quality due to direct contact between positive and negative electrode plates, causing short circuits.
Innovation Solution
A winding device with a compounding mechanism upstream of the winding pin, which laminates and bonds the layers before breaking, and a breaking mechanism that cuts or melts the materials at a compounding region to maintain alignment, preventing springback and misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the breaking mechanism cuts the material layers without prior compounding, then the breaking operation is simple and fast, but the material layers become misaligned due to springback and inconsistent breakage order
Solution Approach 1:
The compounding mechanism performs preliminary bonding of the material layers at the compounding region before the breaking operation. This preliminary action ensures that when the breaking mechanism subsequently cuts the layers, they remain aligned and do not springback inconsistently, thus maintaining manufacturing precision while allowing for efficient breaking operations
2Manufacturing precision
If the compounding mechanism bonds all material layers completely before breaking, then alignment precision is improved, but the device complexity and processing time increase
Solution Approach 1:
The compounding mechanism applies bonding only at the specific compounding region where the breaking will occur, rather than bonding all material layers completely along their entire length. This localized approach maintains alignment precision at the critical breaking point while avoiding unnecessary complexity and processing time for non-critical regions
3Manufacturing precision
If the plural layers of materials are broken simultaneously, then alignment is maintained, but it is difficult to achieve for layers with different breakage points
Solution Approach 1:
The compounding mechanism creates a bonded region at the compounding position before breaking occurs. This preliminary bonding ensures that even when material layers are broken at different times or positions, the bonded region maintains their relative alignment, making the breaking process more feasible without compromising precision
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 solution effectively prevents misalignment of the separator layers, ensuring consistent quality by maintaining the bonded state during and after the breaking process, thereby reducing the risk of short circuits and improving battery performance.
Implementation Method 1
the compounding mechanism includes a first hot melting piece, a second hot melting piece and a driving assembly, the first hot melting piece and the second hot melting piece are oppositely arranged and spaced apart, and the material passes between the first hot melting piece and the second hot melting piece; the driving assembly is connected with the first hot melting piece and/or the second hot melting piece to drive the first hot melting piece and the second hot melting piece to approach each other, so as to bond and compound the plural layers of materials through hot pressing
Implementation Method 2
the breaking mechanism is provided between the compounding mechanism and any winding pin along the preset path and configured to break the compounded plural layers of materials at a compounding region
Data Source
AI summary
A winding device and a material winding method are provided. The winding device is configured to wind a material and includes: a winding switching mechanism, a compounding mechanism and a breaking mechanism. The winding switching mechanism includes a rotating disc and a plurality of winding pins arranged on the rotating disc at intervals. The material is wound around one winding pin along a preset path. The compounding mechanism is provided upstream of the winding pin along the preset path and configured to laminate and then compound the plural layers of materials at a preset position. The breaking mechanism is provided between the compounding mechanism and any winding pin along the preset path and configured to break the compounded plural layers of materials at a compounding region.