UV-Curable Electrode Stacking Adhesive for Alignment Stability
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Solution Overview
Problem
Existing electrode stacking methods in battery cell manufacturing result in misalignment and slippage of electrodes, leading to reduced battery efficiency due to inadequate securing of folds during the folding and pressing processes.
Innovation Solution
The use of an ultraviolet-curable gluing reagent, comprising a multifunctional acrylate crosslinking agent and an initiator, to bond electrode foils to an insulated member, which is cured using UV light, ensuring stable electrode alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional folding and pressing methods are used to secure electrode layers, then the manufacturing process is simple, but the electrode alignment is poor and slippage occurs during transit
Solution Approach 1:
The patent replaces mechanical folding and pressing systems with a chemical bonding system using UV-curable adhesive. The adhesive is applied to insulating members and cured with UV light to bond electrode layers together, eliminating the need for complex mechanical securing mechanisms while providing reliable alignment stability during manufacturing and transit
Solution Approach 2:
The patent changes the physical-chemical state of the adhesive from liquid (applied state) to solid (cured state) through UV irradiation. This parameter change enables the adhesive to transition from a flowable state that can fill gaps between layers to a rigid state that provides strong bonding and prevents slippage, resolving the contradiction between simple application and reliable securing
2Manufacturing precision
If UV-curable gluing reagent is applied to bond electrode layers, then alignment stability is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent introduces UV-curable adhesive as an intermediary substance between electrode layers and insulating members. This intermediary provides precise alignment by bonding surfaces together, and the UV curing mechanism enables rapid setting without requiring complex positioning equipment, thus improving precision without proportionally increasing system complexity
Solution Approach 2:
The patent utilizes the phase transition of the UV-curable adhesive from liquid to solid state upon UV irradiation. This phase transition enables the adhesive to initially flow and conform to surfaces for precise alignment, then rapidly harden to lock the position, achieving high manufacturing precision while keeping the process relatively simple
3Strength
If mechanical pressing is used to secure folds, then the equipment is simple, but the securing strength is insufficient and electrodes may slip
Solution Approach 1:
The patent replaces mechanical pressing systems with photochemical bonding using UV-curable adhesive. The adhesive provides superior bonding strength by forming chemical bonds between surfaces, eliminating the need for high-force mechanical pressing equipment while maintaining ease of manufacture through a simplified application and curing process
4Strength
If adhesive is applied to secure electrode layers, then bonding strength increases, but the curing time may extend manufacturing cycle
Solution Approach 1:
The patent replaces thermal or solvent-based curing mechanisms with UV photochemical curing. This substitution enables rapid bonding strength development because UV curing occurs almost instantaneously upon irradiation, significantly reducing the time required to achieve sufficient bond strength compared to traditional curing methods
Solution Approach 2:
The patent employs periodic UV irradiation to cure the adhesive in stages or zones. By applying UV light in controlled periods or sequences, the manufacturing process can maintain high bonding strength while managing the overall curing time to fit within production cycle requirements
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 UV-curable gluing reagent enhances electrode stack stability and alignment, improving manufacturing efficiency and reliability by preventing slippage and maintaining structural integrity during production and transit.
Implementation Method 1
The ultraviolet-curable gluing reagent is cured using an ultraviolent light source, thereby fixing the electrode stack
Data Source
AI summary
Aspects of the disclosure include ultraviolet-curable gluing reagents and methods of using the same for electrode stacking. An exemplary vehicle includes an electric motor and a battery pack electrically coupled to the electric motor. The battery pack includes a plurality of battery cells, each battery cell having an electrode stack. The electrode stack of each battery cell includes a plurality of battery foils separated by an insulated member in a stacked configuration that includes alternating battery foil and insulated member layers. The electrode stack of each battery cell further includes an ultraviolet-curable gluing reagent. The ultraviolet-curable gluing reagent is applied between the alternating battery foil and insulated member layers, thereby gluing the plurality of battery foils to the insulated member. The ultraviolet-curable gluing reagent includes a multifunctional acrylate crosslinking agent and an initiator.