UV-Cured Battery Foil Stacking for Fold Misalignment Control
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Solution Overview
Problem
Softly packaged lithium-ion batteries face misalignment issues due to unsecured folds during stacking, which can lead to reduced battery efficiency during transportation and storage.
Innovation Solution
A UV-assisted stacking system that uses electrically insulative material formed into folds with UV-activated adhesive applied to create stable foil support surfaces, ensuring secure bonding between battery foils and preventing misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical stacking without adhesive is used, then the stacking process is simple and fast, but the folds are not fully secured allowing electrode misalignment during transport
Solution Approach 1:
A UV-activated adhesive layer is introduced as an intermediary between the insulative material folds and the battery electrodes. This adhesive mediator provides strong bonding to secure folds while maintaining a relatively simple stacking system structure. The adhesive is applied in specific patterns (continuous or discontinuous) to achieve optimal bonding without excessive complexity.
Solution Approach 2:
The adhesive transitions from an inactive state to an active bonded state through UV light activation. This parameter change (from liquid/adhesive state to cured state) allows the system to achieve strong fold security only when needed, maintaining ease of assembly during the stacking process while ensuring reliability during transport and storage.
2Strength
If UV activated adhesive is applied to all foil support surfaces, then bonding strength is maximized, but adhesive material consumption and processing time increase
Solution Approach 1:
Instead of applying adhesive uniformly across all foil support surfaces, the system applies adhesive only to specific locations where bonding is most critical. Discontinuous adhesive patterns (such as at fold edges or specific anchor points) provide sufficient bonding strength while reducing adhesive consumption and curing time, thereby maintaining high stacking productivity.
Solution Approach 2:
The system uses partial adhesive coverage rather than complete coverage of all surfaces. By applying adhesive only to critical bonding zones (such as fold intersections or edge regions), the system achieves adequate bonding strength with reduced processing time and material usage, optimizing the balance between strength and productivity.
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 system enhances the stability and reliability of battery stacks by securely bonding adjacent foil layers, reducing the likelihood of misalignment and improving battery efficiency during transit and storage.
Implementation Method 1
an amount of ultra violet (UV) activated adhesive disposed between the adjacent one of the plurality of foil support surfaces. The amount of UV activated adhesive bonding the adjacent ones of the plurality of foil support surfaces one to another
Data Source
AI summary
A battery stack includes an electrically insulative material formed into a series of folds, the series of folds creating a plurality of foil support surfaces. A battery foil is disposed between adjacent ones of the series of folds. An amount of ultra violet (UV) activated adhesive disposed between the adjacent one of the plurality of foil support surfaces. The amount of UV activated adhesive bonding the adjacent ones of the plurality of foil support surfaces one to another to form a consolidated battery stack.