Ultrasonic Electrode Tab Cutting for Continuous Battery Lamination
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Solution Overview
Problem
Conventional methods for forming electrode tabs in secondary batteries, such as lithium secondary batteries, result in deformation and separation of the electrode mixture layer, require significant space and time for separate notching and lamination processes, and are prone to burr generation and foil deformation.
Innovation Solution
An electrode assembly manufacturing apparatus using an ultrasonic cutter with a cutting unit and lamination unit on the same process line, which forms electrode tabs on an electrode sheet while minimizing deformation and separation, allowing for a continuous manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a press cutter including an upper cutter and a lower cutter is used to form electrode tabs by punching, then electrode tabs can be formed on the electrode sheet, but the distance between the upper cutter and lower cutter must be maintained at 0, requiring significant time for maintenance and adjustment
Solution Approach 1:
The patent replaces the conventional mechanical press cutter system with an ultrasonic cutter that uses ultrasonic vibration to cut the electrode sheet. This substitution eliminates the need for precise mechanical alignment between upper and lower cutters, significantly reducing maintenance time while maintaining high productivity. The ultrasonic cutter forms electrode tabs through vibration-based cutting rather than mechanical pressing, solving the contradiction between ease of operation and productivity.
2Ease of manufacture
If punching is used to form electrode tabs, then electrode tabs can be created, but the electrode mixture layer may be easily cracked and separated from the electrode sheet due to applied pressure
Solution Approach 1:
The patent replaces the high-pressure mechanical punching process with ultrasonic vibration cutting. This substitution prevents the electrode mixture layer from cracking and separating because ultrasonic vibration cuts through material with minimal applied pressure, maintaining layer integrity while still enabling electrode tab formation. The ultrasonic cutter achieves clean cuts without the damaging effects of mechanical pressing.
3Ease of manufacture
If punching is used to form electrode tabs, then electrode tabs can be created, but burrs may be generated on the cut section and the electrode sheet foil may be deformed, deteriorating cut section quality
Solution Approach 1:
The patent replaces mechanical punching with ultrasonic vibration cutting, which eliminates burr generation and foil deformation. The ultrasonic cutter produces clean, precise cuts without the mechanical stress that causes quality deterioration, thereby maintaining both ease of manufacture and high cut section quality simultaneously.
4Productivity
If separate notching and lamination processes are performed, then electrode tabs can be formed and electrodes can be laminated, but a wide space is required for production facilities and automation is difficult
Solution Approach 1:
The patent merges the notching process and lamination process into a single integrated production line. The ultrasonic cutter forms electrode tabs in-line with the lamination process, eliminating the need for separate off-line notching operations. This consolidation reduces facility space requirements while enabling continuous processing and improved automation capability.
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 reduces facility space requirements, minimizes foil deformation and mixture layer separation, and enhances productivity by enabling simultaneous inspection and continuous notching and lamination processes.
Implementation Method 1
an ultrasonic cutter configured to form an electrode tab at the electrode sheet
Data Source
AI summary
An electrode assembly manufacturing apparatus includes an electrode sheet supply unit for supplying an electrode sheet on which electrode mixture coating and non-coating portions are formed, a cutting unit at the rear of the supply unit for forming an electrode tab at the electrode sheet, and a lamination unit at the rear of the supply unit and configured to laminate positive and negative electrodes stacked with a separator between them. A cutting unit die supports the electrode sheet and an ultrasonic cutter spaced from the die forms the tab. A cutting line of a cutting edge of the cutter corresponds to a periphery of a unit electrode in a tab forming direction. The cutting and lamination units are on the same line in a continuous process to reduce a necessary space for electrode assembly manufacture and prevent electrode sheet foil deformation and electrode mixture layer damage in the cut section.