Unified Electrode Assembly Lamination for Battery Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing medium and large size battery modules face challenges such as increased complexity, facility investment, and decreased productivity due to the need for separate processes and equipment for A-type and C-type bicells, leading to inefficiencies in electrode assembly fabrication and alignment.
Innovation Solution
A unified fabricating method for electrode assemblies using a lamination process that forms a unit structure with a first electrode/separator/second electrode/separator/first electrode structure, allowing for the use of common A-type and C-type bicells without additional abrogation, and simplifying the manufacturing process by reducing the need for separate folding apparatuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate processes and equipment are used for A-type and C-type bicells, then manufacturing precision can be maintained, but device complexity and facility investment increase
Solution Approach 1:
The patent merges the manufacturing processes for A-type and C-type bicells into a single unified lamination process. The lamination apparatus is configured to handle both bicell types using the same fundamental process steps and equipment, eliminating the need for separate dedicated processes and reducing overall device complexity while maintaining manufacturing precision through standardized procedures
Solution Approach 2:
The lamination apparatus is designed with multi-functionality to accommodate both A-type and C-type bicells. The same equipment performs lamination operations for different bicell configurations, and the apparatus can be adjusted to handle various electrode assembly structures, achieving versatility without requiring separate specialized equipment for each bicell type
2Manufacturing precision
If separate folding apparatuses are used for different bicell types, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent combines the fabrication capabilities for A-type and C-type bicells into a single integrated lamination process. By using one lamination apparatus to perform all lamination operations for both bicell types, the need for multiple separate folding apparatuses is eliminated, thereby increasing productivity while maintaining precision through consistent process parameters
Solution Approach 2:
The unified lamination process enables continuous operation without requiring switching between different specialized apparatuses. The lamination apparatus can continuously process both A-type and C-type bicells using the same operational sequence, eliminating idle time and setup changes associated with switching between separate equipment, thus improving overall fabrication efficiency
3Reliability
If multiple types of unit structures are manufactured separately, then reliability is improved, but loss of time increases
Solution Approach 1:
The patent implements preliminary preparation of all necessary materials and process parameters before actual lamination begins. The lamination apparatus is pre-configured to handle both A-type and C-type bicell requirements, and all process conditions are standardized in advance, allowing rapid production of different bicell types without time-consuming setup changes, thus reducing manufacturing cycle time while maintaining quality reliability
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 simplifies and unifies the fabrication of medium and large size lithium ion polymer batteries, decreases facility investment, and increases productivity by using existing lamination apparatuses for both bicell types, resulting in a more efficient and cost-effective manufacturing process.
Implementation Method 1
conducting a first process of laminating and forming a bicell having a first electrode/separator/second electrode/separator/first electrode structure
Data Source
AI summary
A fabricating method of a unit structure for accomplishing an electrode assembly formed by a stacking method, and an electrochemical cell including the same are disclosed. The fabricating method of the electrode assembly is characterized with fabricating the unit structure by conducting a first process of laminating and forming a bicell having a first electrode/ separator/ second electrode/ separator/ first electrode structure, conducting a second process of laminating a first separator on one of the first electrode among two of the first electrodes, and conducting a third process of laminating second separator/second electrode one by one on the other first electrode among the two of the first electrodes.