Wound Battery Core Formation Using Continuous Web Conveying
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing flat batteries using wound core structures are inefficient due to non-continuous batch processing, leading to high production costs and time, which are then passed on to the finished product.
Innovation Solution
A method and apparatus involving a web-conveying element with lay-down stations for discrete or continuous web elements, including anode, cathode, and separator materials, where the materials are arranged in a predetermined pattern and wound using a gripper assembly to form a spiral wound core, utilizing a vacuum system and adhesive application for stabilization and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If non-continuous batch processing is used to assemble wound core structures, then manufacturing flexibility is maintained, but production speed is low and costs are high
Solution Approach 1:
The patent implements continuous processing by conveying web elements through a series of lay-down stations that continuously deposit anode, cathode, and separator materials onto a moving conveyor belt, eliminating batch processing interruptions and maintaining constant production flow
Solution Approach 2:
The patent divides the continuous web elements into discrete wound core structures by positioning multiple lay-down stations at specific intervals along the conveyor, with each station independently depositing materials to form separate wound elements that are then cut and wound individually
2Productivity
If continuous high-speed processing is implemented, then production efficiency increases, but precise positioning and alignment of web elements become more difficult
Solution Approach 1:
The patent employs sensors and control systems that monitor the position of web elements on the conveyor belt in real-time, providing feedback to adjust the timing and positioning of material deposition at each lay-down station to ensure precise alignment despite high-speed continuous processing
Solution Approach 2:
The patent pre-positions multiple lay-down stations at predetermined intervals along the conveyor belt, with each station configured to deposit materials at specific locations before the web elements arrive, ensuring precise positioning is maintained throughout continuous high-speed operation
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 enables a high-speed, efficient production process for wound power cell cores, reducing production time and costs by stabilizing and bonding the web elements effectively, resulting in a cost-effective and efficient manufacturing process.
Implementation Method 1
utilizing a vacuum system and adhesive application for stabilization and bonding
Implementation Method 2
utilizing a vacuum system and adhesive application for stabilization and bonding
Data Source
AI summary
A method and apparatus for the production of wound elements. The method comprising: providing a plurality of first electrical web elements; disposing at least one of the first electrical web elements upon a conveying element, wherein a first or second face of the disposed first electrical web elements is disposed in a face to face relationship with the conveying element; providing a plurality of second electrical web elements; disposing at least one of the second electrical web elements upon the conveying element at a predetermined spacing from the disposed first electrical web elements and in a face to face relationship with the conveying element, wherein the predetermined spacing is at least as long as the length of the first electrical web element; and disposing an electrically insulating separator web element in a face to face relationship with the disposed electrical web elements.