Stepped Battery Separator Pressing for Pouch Defect Prevention
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Solution Overview
Problem
The tent shape formed by the separation film in stepped batteries manufactured through a stack and folding process interferes with the pouch, causing defects such as film breakage and electrode misalignment during packaging.
Innovation Solution
A method and device where a press tool with a shape corresponding to the stepped surface is used to press and shape the tent portion of the separation film, attaching a separator surplus part to cover the stepped surface, thereby preventing interference with the pouch and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cells are stacked in a folding manner to form stepped surfaces, then manufacturing convenience is improved, but tent shapes form on the separation film causing interference with the pouch
Solution Approach 1:
The patent applies preliminary action by pressing the separation film to remove tent shapes immediately after the stacking process, before the pouch packaging step. This prevents the tent shapes from interfering with subsequent pouch accommodation while maintaining the manufacturing advantages of the stacking method.
Solution Approach 2:
The patent applies preliminary anti-action by using a pressing device to counteract and eliminate the tent shape formation caused by stacking. The press applies force in the opposite direction to the tent shape protrusion, flattening the separation film surface before pouch packaging occurs.
2Object-generated harmful factors
If the separation film is pressed to remove tent shapes, then interference with the pouch is prevented, but additional manufacturing steps are required
Solution Approach 1:
The patent merges the pressing operation with the existing manufacturing flow by positioning the pressing device to operate on the separation film during or immediately after the stacking process. This integration reduces the need for separate dedicated pressing steps and minimizes additional process complexity.
3Reliability
If the separation film is pressed to remove tent shapes, then defects during packaging are prevented, but manufacturing time increases
Solution Approach 1:
The pressing operation is performed as a preliminary action immediately after stacking and before pouch packaging. By eliminating tent shapes at this early stage, the patent prevents potential defects during packaging without requiring separate corrective steps later, thereby minimizing total manufacturing time.
Solution Approach 2:
The patent implements a rapid pressing operation that quickly flattens the separation film surface. The pressing device is designed to apply sufficient force in a short duration to remove tent shapes efficiently, minimizing the time added to the manufacturing process while ensuring defect prevention.
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 approach effectively prevents defects by ensuring the separation film does not interfere with the pouch, maintaining electrode alignment, and simplifies the process by integrating the hot press operation to shape the tent portion, reducing the number of manufacturing steps.
Implementation Method 1
pressing the tent portion by using a press tool (30) having a shape corresponding to the stepped surface (18) of the stepped battery (10) placed on a lower jig
Data Source
AI summary
Provided are a stepped battery and a method and device for manufacturing the stepped battery, and more particularly, a stepped battery and a method and device for manufacturing the stepped battery, which processes a tent part of a separation film formed on a stepped part of the stepped battery, to prevent a defect from occurring during a subsequent process. A stepped battery manufacturing method includes preparing a stepped battery (10) having a tent portion of a separation film (16) formed on at least one stepped surface (18), and pressing the tent portion by using a press tool (30) having a shape corresponding to the stepped surface (18) of the stepped battery (10).