Step Lithium Ion Cells via Segmented Electrode Coating
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Solution Overview
Problem
Conventional lithium ion batteries are inefficiently used in portable electronic devices due to their regular cuboid shape, which does not align with the step-shaped or irregular spaces within these devices, making it difficult to manufacture step lithium ion batteries efficiently.
Innovation Solution
A method involving coating a collector roll with zebra stripe patterns, compacting it, cutting it into anode and cathode plates with tabs and rounded corners, recombining with separators, and hot pressing to form step lithium ion cells that can be efficiently stacked and molded into irregular shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cuboid-shaped lithium ion batteries are used, then manufacturing is simple and efficient, but space utilization in portable electronic devices is poor
Solution Approach 1:
The battery is divided into multiple electrode plates (anode and cathode) of different sizes that are stacked in sequence, creating a step-shaped structure. This segmentation allows the battery to conform to irregular spaces while maintaining efficient manufacturing through standardized plate production and assembly processes
Solution Approach 2:
Multiple electrode plates of progressively smaller sizes are nested within each other in a stacked configuration, with each plate positioned to maximize space utilization. The separator and other components are similarly nested between the electrode plates, creating a compact step-shaped structure that fits irregular device spaces
2Volume of moving object
If step lithium ion batteries are manufactured using conventional methods, then space utilization is improved, but manufacturing complexity and difficulty increase
Solution Approach 1:
Tabs and rounded corners are formed on the electrode plates during the coating and cutting stages before assembly. This preliminary formation of features that would otherwise require complex post-processing operations simplifies the overall manufacturing process while enabling the step-shaped configuration
Solution Approach 2:
Traditional mechanical cutting and shaping methods are replaced with coating techniques that directly form the desired plate shapes and tab structures. The coating process inherently creates the necessary geometric features, eliminating separate mechanical processing steps and reducing manufacturing complexity
3Productivity
If step lithium ion batteries are manufactured continuously, then productivity is improved, but manufacturing process complexity increases
Solution Approach 1:
The manufacturing process is designed as a continuous operation where collector rolls are coated, compacted, cut into electrode plates with tabs and rounded corners, assembled with separators, and hot-pressed in sequence without interruption. This continuous flow approach maintains high productivity while standardizing each process stage to manage complexity
Solution Approach 2:
The coating process performs multiple functions simultaneously: it deposits active material, forms tabs through selective coating patterns, and creates rounded corners through the coating geometry. This multi-functionality reduces the number of separate process steps required, managing complexity while enabling continuous manufacturing
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 method enhances production efficiency and allows for continuous molding of step lithium ion cells, enabling them to be accommodated in various irregular spaces within portable devices without significant reduction in production efficiency.
Implementation Method 1
coating a collector roll along an unreeling direction thereof to form one or more strip coated areas
Implementation Method 2
compacting the coated collector roll in step 1) to obtain a compacted collector roll having a predetermined compaction density
Implementation Method 3
hot pressing the stacked primary cell to form a whole lithium ion cell via bonding of the anode plates/cathode plates with the separators
Data Source
AI summary
A method for manufacturing lithium ion cells includes the steps of: 1) coating a collector roll along an unreeling direction thereof to form one or more strip coated areas, two side edges of the coated area each being provided with an uncoated area to form tabs thereon; 2) compacting the coated collector roll and obtaining a compacted collector roll; 3) cutting the compacted collector roll into anode plates/cathode plates having different sizes each having a tab and rounded corners; 4) recombining an anode plate/a cathode plate with a separator; cutting the separator after recombination to form rounded corners at a position corresponding to the rounded corners of the anode plate/cathode plate and further obtain a mono-cell or a half-cell having different sizes; 5) stacking the mono-cells and half-cells into a step preliminary cell; and 6) hot pressing the stacked preliminary cell to form a whole lithium ion cell via bonding of the anode plates/cathode plates with the separator.