Z-Fold Electrode Assembly Alignment Using Pre-Applied Adhesive
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Solution Overview
Problem
Conventional Z-folding type electrode assemblies in battery cells face issues with electrode displacement due to lack of alignment during the stacking process, leading to reduced adhesive strength and inadequate heat transfer, especially when using separators with low adhesive strength.
Innovation Solution
An apparatus and method for manufacturing an electrode assembly that includes a separator supply unit, a table, a separator guide, and upper adhesive supply units to ensure precise alignment and adhesion of electrodes and separator sheets in a zigzag folding pattern, preventing electrode displacement and enhancing adhesive strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate stacking alignment process is performed after stacking electrodes and separator sheet, then alignment precision is improved, but the overall thickness of the stacked body increases and adhesive strength is lowered
Solution Approach 1:
The patent applies adhesive to the separator sheet before stacking the electrodes, performing the bonding action in advance. This preliminary application of adhesive ensures proper alignment during the stacking process itself, eliminating the need for a separate post-stacking alignment process that would increase thickness and reduce adhesive strength.
2Device complexity
If electrodes and separator sheet are stacked without separate alignment process, then manufacturing complexity is reduced, but electrodes become displaced from fixed positions
Solution Approach 1:
The adhesive is applied to the separator sheet before stacking, creating immediate bonding that prevents electrode displacement. This preliminary bonding action ensures position stability during stacking without requiring complex post-stack alignment processes or additional structural elements.
Solution Approach 2:
The adhesive acts as an intermediary substance between the separator sheet and electrodes, facilitating proper alignment and preventing displacement. This intermediary material enables simple stacking processes while maintaining high position stability, resolving the contradiction between manufacturing simplicity and reliability.
3Strength
If adhesive is applied to electrodes and separator sheet before stacking, then adhesive strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines the adhesive application step with the stacking process itself, rather than treating them as separate operations. The adhesive is applied to the separator sheet immediately before stacking, merging two process steps into one integrated operation that improves adhesive strength without significantly increasing manufacturing complexity.
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 prevents electrode displacement and improves the alignment and adhesive strength between electrodes and separators, reducing the thickness of the assembly and maintaining efficient heat transfer, thereby enhancing the performance and reliability of battery cells.
Implementation Method 1
upper adhesive supply units to ensure precise alignment and adhesion of electrodes and separator sheets
Data Source
AI summary
An apparatus for manufacturing an electrode assembly includes a separator supply unit, a table, a separator guide, and a pair of upper adhesive supply units. The separator supply unit is configured for supplying a separator sheet from which a separator is formed. The table is configured for supporting an electrode and a portion of the separator sheet. The separator guide is configured for guiding the separator sheet to fold in a particular folding direction. The pair of upper adhesive supply units are configured for applying an adhesive to at least a part of an uppermost electrode supported by the table. The separator guide and the pair of upper adhesive supply units are configured for translation over and relative to the table. The electrode assembly is manufactured by a process using the apparatus.