Zigzag Electrode Assembly Folding for Precise Separator Alignment
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Solution Overview
Problem
The conventional methods for manufacturing stacked or folded type electrode assemblies are complex, leading to inefficiencies in manufacturing, unnecessary gaps between electrodes and separators, and difficulties in controlling separator tension, which affect the quality and durability of battery cells.
Innovation Solution
An electrode assembly folding apparatus that uses a zigzag stacking method with a supply unit, holding unit, and stack unit, where sheet-shaped separators and electrodes are alternately positioned, and a detection unit ensures precise alignment and folding, minimizing equipment scale and maximizing production speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional sequential stacking method is used to manufacture electrode assemblies, then the manufacturing process can be completed, but the procedure becomes complicated and unnecessary gap spaces are generated between electrodes and separators
Solution Approach 1:
The patent merges the stacking and folding operations into a single integrated process. The electrode assembly is stacked in a zigzag pattern and then folded back on itself, combining what were previously separate manufacturing steps into one continuous operation that eliminates unnecessary gaps and simplifies the overall process.
Solution Approach 2:
Instead of stacking electrodes and separators separately and then folding, the patent inverts the approach by stacking the electrode assembly in a zigzag pattern first and then folding the entire assembly back. This reversal of the conventional sequence eliminates the need for separate bi-cell manufacturing and attachment steps.
2Ease of manufacture
If zigzag stacking method is used to manufacture electrode assemblies, then the manufacturing process is simplified, but the supplied electrodes may move during the stacking process
Solution Approach 1:
The patent applies preliminary action by using a suction holding unit to secure electrodes to the separator before the stacking operation begins. This pre-holding mechanism prevents electrode movement during the zigzag stacking process, ensuring reliability while maintaining the simplified manufacturing approach.
3Productivity
If conventional stacking method is used for long length battery cells, then manufacturing can be completed, but it is difficult to control separator tension and progress speed is slow
Solution Approach 1:
The patent applies dynamics by using a suction holding unit that can dynamically adjust and maintain appropriate tension on the separator during the zigzag stacking process. This dynamic tension control enables faster manufacturing speeds while maintaining precision, particularly for long length battery cells where tension control is critical.
Data Source
AI summary
An electrode assembly folding apparatus for folding an electrode assembly in a zigzag shape according to one embodiment of the present disclosure includes: a supply unit for supplying the electrode assembly that comprises two sheet-shaped separators, a second electrode continuously located between inside surfaces of the separators facing each other, and a first electrode alternately located up and down on outside surfaces of the two separators, wherein a first unit body and a second unit body are alternately connected to each other, with the first electrode of the first unit body being located on an upper side and the first electrode of the second unit body being located on a lower side, a holding unit that holds and transfers the first unit body supplied from the supply unit, and a stack unit that stacks the first unit body transferred by the holding unit.