Zigzag Electrode Assembly Folding for Gap-Free Separator Stacking
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Solution Overview
Problem
Conventional methods for manufacturing stacked or stacked/folding type electrode assemblies are complex, leading to inefficiencies, gaps between electrodes and separators, and risks of electrode movement during stacking, which affect manufacturing efficiency and product durability.
Innovation Solution
An electrode assembly folding apparatus and method that employs a zigzag stacking process using a holding unit with a swing motion to alternately fold and stack electrodes between separators, utilizing a suction device for precise handling and alignment, and a detection unit for positional adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional sequential stacking method is used to manufacture electrode assemblies, then the manufacturing process can be completed, but the procedure becomes complicated and unnecessary gap space is generated between electrode and separator
Solution Approach 1:
The electrode assembly is divided into multiple unit bodies, each comprising a separator with electrodes attached. These unit bodies are then stacked in sequence to form the complete electrode assembly, allowing for precise control of each segment while simplifying the overall manufacturing process
Solution Approach 2:
Electrodes are pre-attached to separators in unit bodies before final stacking. This preliminary assembly ensures proper positioning and eliminates gap space between electrodes and separators during the subsequent stacking process
2Productivity
If zigzag stacking method is used to manufacture electrode assemblies, then manufacturing efficiency can be improved, but cut electrodes must be separately stored and supplied electrodes may move during stacking process
Solution Approach 1:
The electrode assembly is segmented into multiple unit bodies that are stacked in a zigzag pattern. This segmentation allows continuous processing without separate storage of cut electrodes, as each unit body is immediately stacked in sequence
Solution Approach 2:
The stacking process uses dynamic zigzag motion to alternately stack unit bodies from opposite sides toward the center. This dynamic approach maintains electrode position stability through controlled movement while achieving high manufacturing efficiency
3Productivity
If conventional stacking method is used for long length battery cells, then manufacturing can be completed, but tension control of separator becomes difficult and progress speed is slow
Solution Approach 1:
The long electrode assembly is divided into multiple unit bodies of manageable length. Each unit body maintains proper separator tension independently, and the complete long battery cell is formed by stacking these controlled segments in zigzag pattern
Solution Approach 2:
The stacking process transitions from linear sequential stacking to two-dimensional zigzag stacking. Unit bodies are alternately stacked from opposite sides toward the center, enabling better tension control while significantly increasing progress speed through parallel processing
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 apparatus simplifies the manufacturing process, reduces equipment scale, prevents electrode movement, and enhances production speed while improving product quality and durability.
Implementation Method 1
utilizing a suction device for precise handling and alignment
Data Source
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AI summary
An electrode assembly folding apparatus according to one embodiment of the present disclosure includes: a supply unit for supplying the electrode assembly that comprises two sheet-shape separators, a second electrode continuously located between inside surfaces of the separators facing each other, and a first electrode alternately located up and down on outside surfaces of the two separators, wherein a first unit body and a second unit body are alternately connected to each other, and wherein the first electrode of the first unit body is located at an upper side and the first electrode of the second unit body is located at a lower side, a holding unit that holds the first unit body supplied from the supply unit and transfers it through a swing motion, thereby folding the electrode assembly in a zigzag shape, and a stack unit that stacks the first unit body transferred by the holding unit.