Battery Unit Cell Separator Cutting With Thermal Fusion Sealing
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Solution Overview
Problem
In the manufacturing of secondary battery unit cells, the existing methods fail to prevent the folding and scattering of separators and electrodes during the cutting process, leading to potential short circuits when the separators are cut.
Innovation Solution
An apparatus and method where the upper and lower separators are continuously moved in a longitudinal direction and cut between electrodes, using a heated cutter that thermally fuses and cuts the separators, with a fixed part and movable part configured to apply heat and pressure, ensuring simultaneous cutting and sealing to prevent folding and scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the separators are cut after laminating the electrodes and separators using heat and pressure, then the unit cells can be manufactured, but the separators may fold or scatter during cutting causing short circuits
Solution Approach 1:
The patent applies preliminary action by bonding the upper and lower separators together before the cutting operation. The laminating device bonds the separators to each other and to the electrodes in advance, creating a unified structure that prevents folding and scattering during subsequent cutting. This preliminary bonding ensures separator integrity while enabling successful unit cell manufacturing.
2Productivity
If the separators are continuously supplied without cutting, then the manufacturing process can proceed, but the separators cannot be separated into individual unit cells
Solution Approach 1:
The patent merges the cutting operation with the laminating operation by integrating the cutter into the laminating device. The laminating device performs both functions: it bonds the separators and electrodes together while simultaneously cutting them to the desired length. This combination enables continuous manufacturing while achieving proper unit cell separation, resolving the contradiction between productivity and ease of manufacture.
3Ease of manufacture
If a cutter is used to cut the separators, then the separators can be separated, but the cutting pressure may cause folding of the separators
Solution Approach 1:
The patent combines the cutting function with the laminating function in a single integrated device. The cutter is incorporated into the laminating device, allowing simultaneous bonding and cutting operations. The bonding action prevents separator folding during cutting by holding the separators firmly against the electrodes, while the cutting action separates the unit cells. This merging eliminates the shape distortion problem that occurs with separate cutting operations.
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 solution effectively suppresses the folding and scattering of separators and electrodes, ensuring secure bonding and preventing short circuits by thermally fusing the separators during the cutting process, thus enhancing the manufacturing process for secondary battery unit cells.
Implementation Method 1
a cutter coupled to the movable part, heated to a predetermined temperature, and configured to cut the upper separator and the lower separator, wherein the lower separator and the upper separator are cut by the cutter and thermally fused while passing between the fixed part and the movable part
Data Source
AI summary
The present invention provides an apparatus for manufacturing a unit cell, in which a lower separator and an upper separator continuously move in a longitudinal direction, and the lower separator and the upper separator are cut between electrodes adjacent to each other in a process of manufacturing the unit, which is provided in a state in which the electrodes are stacked between the lower separator and the upper separator and on the upper separator, respectively, the apparatus comprising: a fixed part disposed under the lower separator and heated to a predetermined temperature; a movable part aligned with the fixed part in a vertical direction on the upper separator; and a cutter coupled to the movable part, heated to a predetermined temperature, and configured to cut the upper separator and the lower separator, wherein the lower separator and the upper separator are thermally fused between the fixed part and the movable part and cut by the cutter while passing between the fixed part and the movable part.