Thermal Composite Cell Lamination With Hot-Press Z-Folding Alignment
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Solution Overview
Problem
Conventional lithium battery lamination methods suffer from electrode plate staggering issues, poor safety, complex and inefficient processes, and high production costs, limiting their development and application in the new energy market.
Innovation Solution
A method and system for manufacturing thermal composite cells involving diaphragm unwinding, hot-pressing and compositing electrode plates on both sides with pre-heating and pressing, followed by Z-shaped folding and pressing to form a composite stack, utilizing suction surfaces and CCD positioning for precise placement and bonding, and pre-coating with composite glue for enhanced bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lamination methods (Z-shaped, bag-making, or composite lamination) are used, then the cell can be manufactured with basic structure, but the electrode plates easily stagger causing short circuit and poor safety
Solution Approach 1:
The patent applies preliminary action by pre-coating the diaphragm with composite glue before hot-pressing the electrode plates. This pre-coating ensures that the bonding material is already in position and at optimal temperature when the electrode plates are pressed onto the diaphragm, preventing stagger and ensuring precise alignment from the outset rather than attempting to correct misalignment after bonding occurs.
Solution Approach 2:
The patent utilizes parameter changes by controlling the temperature and pressure parameters during the hot-pressing process. The diaphragm is heated to a specific temperature range to activate the composite glue, and controlled pressure is applied during hot-pressing to ensure precise bonding without causing electrode plate deformation or stagger, thereby improving both safety and lamination accuracy.
2Productivity
If conventional lamination methods are used, then the cell structure can be formed, but the process is complicated and lamination efficiency is low
Solution Approach 1:
The patent merges multiple operations into a single integrated hot-pressing step. Instead of performing separate coating, drying, and bonding operations as in conventional methods, the patent combines these functions into one hot-pressing process where the diaphragm is pre-coated with composite glue and then hot-pressed with the electrode plates simultaneously, simplifying the process while improving efficiency.
Solution Approach 2:
The pre-coating of the diaphragm with composite glue before assembly is a preliminary action that eliminates the need for subsequent coating operations during the lamination process. This preliminary preparation simplifies the overall process flow and reduces the number of processing steps required, thereby improving lamination efficiency without increasing device complexity.
3Ease of manufacture
If conventional lamination methods are used, then basic cell production can be achieved, but production costs are high
Solution Approach 1:
By merging the coating and bonding operations into a single hot-pressing step, the patent reduces the number of processing stages required. This consolidation decreases equipment requirements, reduces operational complexity, and improves throughput, all of which contribute to lowering production costs while maintaining or improving lamination efficiency.
Solution Approach 2:
The composite glue acts as an intermediary material that enables bonding between the diaphragm and electrode plates during the hot-pressing process. By using this intermediary bonding agent, the patent achieves reliable adhesion in a single step rather than requiring multiple separate operations, thereby reducing manufacturing costs while maintaining high lamination efficiency.
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 method achieves high lamination accuracy, quality, and efficiency, improving safety and reducing production costs while facilitating automatic operation and precise overlap, addressing the shortcomings of existing methods.
Implementation Method 1
a first electrode plate is hot-pressed and composited on a first side of the diaphragm, and a second electrode plate is hot-pressed and composited on a second side of the diaphragm
Implementation Method 2
both the first hot-pressing and compositing device and the second hot-pressing and compositing device have a pre-heating and pressing function
Implementation Method 3
The first electrode plate rotating table has at least one first suction surface and rotationally conveys the first electrode plate to a preset hot-pressing and compositing position through the first suction surface
Implementation Method 4
pre-coating with composite glue for enhanced bonding
Data Source
AI summary
Provided are a method and system for manufacturing a thermal composite cell. The method for manufacturing a thermal composite cell includes the following steps: unwinding a diaphragm and unwinding the diaphragm by a diaphragm unwinding device; hot-pressing and compositing electrode plates, hot-pressing and compositing a first electrode plate on a first side of the diaphragm 1, and hot-pressing and compositing a second electrode plate on a second side of the diaphragm; performing Z-shaped folding on the diaphragm and the electrode plates; and performing pressing to form a cell. The system for manufacturing a thermal composite cell includes a diaphragm unwinding device, an electrode plate conveying device, a heat-pressing and compositing device, a folding thimble, and a pressing device.