Serpentine Induction Heating Coil for Uniform Electrode Assembly Bonding
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Solution Overview
Problem
The existing methods for bonding electrodes and separators in electrode assemblies are inefficient due to non-uniform application of heat and pressure, leading to inconsistent adhesive forces and performance.
Innovation Solution
An induction heating device with a specifically designed induction heating coil, featuring a meandering serpentine pattern and a two-layer structure, is used to uniformly heat the electrode assembly, ensuring consistent adhesive forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat and pressure are applied to bond electrodes and separator in the stack, then bonding is achieved, but heat and pressure cannot be uniformly applied due to difference in stacked positions, resulting in non-constant adhesive force
Solution Approach 1:
The patent replaces the conventional thermal conduction heating method with induction heating technology. The induction heating coil generates an electromagnetic field that directly induces eddy currents in the electrodes, converting electromagnetic energy into heat within the workpiece itself. This substitution enables rapid and uniform heating throughout the stack, resolving the issue of non-uniform heat distribution that occurs with conventional heating methods where heat must conduct through layers from the heating plate.
Solution Approach 2:
The serpentine pattern of the induction heating coil creates a distributed electromagnetic field that effectively vibrates or agitates the heating energy across the entire stack area. The meandering path of the coil ensures that electromagnetic energy is delivered uniformly to all regions of the stacked electrodes and separator, preventing localized heating variations and ensuring consistent adhesive force throughout the assembly.
2Temperature
If a conventional coil shape is used for induction heating, then induction heating can be performed, but uniformity in temperature distribution cannot be secured
Solution Approach 1:
The patent employs a serpentine (meandering) coil pattern instead of a simple circular or linear configuration. This curved, winding path allows the coil to distribute electromagnetic energy more evenly across the heating area. The serpentine geometry ensures that no region is too far from the coil windings, creating a more uniform temperature distribution throughout the stacked electrodes and separator while maintaining a relatively simple single-layer coil structure.
Solution Approach 2:
The induction heating coil is positioned in a plane parallel to the stacked electrodes rather than perpendicular to them. This dimensional arrangement allows the electromagnetic field to penetrate through the stack uniformly across its entire surface area. The coil's planar configuration with serpentine pattern distributes heating energy across the two-dimensional surface of the stack, achieving uniform temperature distribution without requiring complex three-dimensional coil structures.
3Strength
If heat and pressure are applied for a long time to ensure uniform bonding, then adhesive force can be improved, but manufacturing time and energy consumption increase
Solution Approach 1:
The induction heating process operates by applying electromagnetic energy in a controlled periodic manner through alternating current in the coil. This periodic electromagnetic field generation creates rapid cyclic heating that efficiently transfers energy to the electrodes through induced eddy currents. The periodic action allows for precise control of the heating process, achieving uniform bonding in significantly reduced time compared to continuous conventional heating methods.
Solution Approach 2:
The induction heating coil maintains continuous electromagnetic field generation across the entire stack surface simultaneously, rather than heating sequentially from one point or through thermal conduction. This continuous and simultaneous heating action throughout the stack enables all layers to reach bonding temperature at the same time, dramatically reducing the overall manufacturing time while maintaining uniform adhesive force across all electrodes and separator interfaces.
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 induction heating device achieves uniform heat distribution, reducing temperature non-uniformity and adhesive force deviations, resulting in electrode assemblies with consistent performance.
Implementation Method 1
an induction heating coil which includes a first part extending at a first predetermined depth along the thickness direction of the induction heating plate, forming a meandering serpentine pattern, and a second part extending along a periphery of the induction heating plate at a second predetermined depth along the thickness direction of the induction heating plate
Implementation Method 2
at least one induction heating plate... an induction heating coil built in the induction heating plate
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
The present invention is to provide an induction heating device, a method for manufacturing an electrode assembly using the same, and an apparatus for manufacturing an electrode assembly including the same.