Wound Electrode Heat Bonding to Prevent Loosening and Bulk
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Solution Overview
Problem
Conventional methods for securing wound electrode arrangements in battery assembly, such as using adhesive tape, lead to loosening and increased volume, making it difficult to maintain the initial tight wind and requiring skilled personnel for smaller electrodes, resulting in high reject rates.
Innovation Solution
A bonding system that uses a heating assembly and indexing assembly to apply pressure and heat, heat-bonding the outermost wind layer to the underlying layer without additional adhesive, maintaining the initial tension and minimizing volume, suitable for both large and small electrode arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive tape is used to secure the electrode arrangement, then the electrode arrangement is secured against loosening, but the diameter and volume of the electrode arrangement increase
Solution Approach 1:
The bonding system merges the heating and pressing functions into a single integrated assembly that applies both heat and pressure simultaneously to the electrode arrangement, eliminating the need for separate adhesive tape application and achieving securement without additional volume
Solution Approach 2:
The patent replaces the mechanical adhesive tape system with a thermal-mechanical bonding system that uses controlled heating and pressing to achieve securement, substituting the need for adhesive materials with a process-based solution
2Ease of manufacture
If components are cut from their sources prior to securing, then adhesive tape can be applied, but the tension in the electrode arrangement is released causing loosening
Solution Approach 1:
The bonding system performs the securing operation before the components are cut from their sources, maintaining the tension and tight winding of the electrode arrangement throughout the bonding process, thus preventing loosening that would occur if cutting happened first
3Reliability
If adhesive tape is applied to secure smaller electrode arrangements, then securing is achieved, but alignment and application become difficult requiring skilled personnel
Solution Approach 1:
The bonding system is designed with universal applicability to handle electrode arrangements of various sizes through the indexing assembly that can index to different positions, making the same bonding process effective for both large and small electrode arrangements without requiring different methods or skilled manual intervention
4Reliability
If adhesive tape is used to secure larger electrode arrangements, then securing is achieved, but the process is less efficient compared to smaller arrangements
Solution Approach 1:
The bonding system utilizes parameter changes including temperature, pressure, and indexing position to adapt the bonding process to different electrode arrangement sizes, enabling efficient and reliable securing across the full range of sizes with a single automated system
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 effectively secures wound electrode arrangements without additional material, maintaining the initial tightness and reducing the occupied volume, allowing more active material in the battery housing and improving the discharge capacity.
Implementation Method 1
The heating assembly includes a housing that supports a distally extending resistive heating element. The controller operates the bonding system to heat the heating element to a predetermined temperature.
Implementation Method 2
The controller operates the bonding system to effectuate a movement of the transfer assembly in a distal direction to apply a predetermined amount of pressure to an exterior of a wound electrode arrangement supported on the mandrel
Data Source
AI summary
A winding system includes a housing, a winding assembly, a bonding system, and a controller. The winding assembly is configured to wind electrode components about a mandrel to form a wound electrode arrangement. The bonding system includes an indexing assembly and a heating assembly. The indexing assembly includes a stationary support assembly and a transfer assembly moveably secured relative to the support assembly. The heating assembly is secured to a distal end of the transfer assembly. The heating assembly includes a housing that supports a distally extending resistive heating element. The controller operates the bonding system to effectuate a movement of the transfer assembly in a distal direction to apply a predetermined amount of pressure to an exterior of a wound electrode arrangement supported on the mandrel, and to heat the heating element to a predetermined temperature.