Zigzag Electrode Stacking for Battery Alignment
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Solution Overview
Problem
The manufacturing process of rechargeable batteries, particularly through the winding and stacking methods, faces inefficiencies due to erroneous alignment and increased manufacturing time, leading to potential failures and reduced productivity, especially as electrode sizes increase.
Innovation Solution
A method involving continuous supply and bending of electrode plates with separators in a zigzag structure, followed by alignment and stacking with adhesive application, simplifies the process and improves productivity by eliminating the need for separate cutting and attachment steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the electrode assembly is manufactured by a stacking method with pre-cut electrode plates and separators, then the alignment accuracy is improved, but the manufacturing time increases due to additional attachment processes
Solution Approach 1:
The electrode plates are supplied with pre-formed bent portions at predetermined positions before the stacking process. This preliminary formation of the bent structure eliminates the need for time-consuming attachment processes during assembly, while maintaining accurate alignment through the pre-designed geometry that guides proper positioning during stacking
2Ease of manufacture
If the can is formed in a rectangular parallelepiped shape with spiral-winding method, then the manufacturing process is simplified, but the active material may be peeled at bent portions and the electrode assembly may be twisted
Solution Approach 1:
The electrode plate is divided into multiple active material portions separated by bent portions. This segmentation allows the electrode assembly to accommodate the rectangular can shape without continuous bending stress, preventing peeling at bent portions while maintaining structural integrity and eliminating the need for complex winding processes
3Quantity of substance
If the size of electrode plates and separators is increased to enhance battery capacity, then the battery characteristics are improved, but erroneous alignment occurs and manufacturing failures increase
Solution Approach 1:
The electrode plate incorporates bent portions with specific curvature radii (R1 and R2) at predetermined positions. These curved features serve as alignment guides that maintain positioning accuracy even when the overall electrode plate size is increased, preventing erroneous alignment while allowing for larger active material areas to enhance battery capacity
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 enhances manufacturing efficiency by ensuring accurate alignment and integration of electrode plates and separators, reducing the risk of material peeling and twisting, thereby improving battery characteristics and productivity.
Implementation Method 1
an adhesive may be coated on both surfaces of the separator, and a plurality of positive electrode plates and negative electrode plates cut to a predetermined size may be alternately stacked with the separator therebetween
Data Source
AI summary
A method of manufacturing a rechargeable battery includes continuously supplying a first electrode plate, the first electrode plate including a plurality of first active material portions with gaps therebetween on a first current collector, continuously supplying a first separator and a second separator to respective surfaces of the first electrode plate, bending the first electrode plate with the first and second separators to form a zigzag structure with bent portions, supplying a second electrode plate to an inside of each bent portion of the zigzag structure, the second electrode plate including a second active material portion on a second current collector, aligning and stacking the first electrode plate, the first separator, the second separator, and the second electrode plate, and taping the aligned and stacked first electrode plate, first separator, second separator, and second electrode plate at an outermost side thereof.