Electrode Assembly Manufacturing Apparatus and Electrode Assembly Manufactured Using the Same

The present invention relates to an electrode assembly manufacturing apparatus including a first separator supply unit configured to supply a first separator sheet from a first separator roll, a first electrode supply unit configured to supply a first unit electrode from a first electrode roll, a second separator supply unit configured to supply a second separator sheet from a second separator roll, an anti-wrinkle unit configured to hold the first separator sheet and the second separator sheet to apply tension thereto, a surface treatment unit configured to form an embossed pattern on each of the first separator sheet and the second separator sheet, a lamination unit configured to apply heat and pressure to the first separator sheet, the first unit electrode, and the second separator sheet, and a cutting unit configured to cut the first separator sheet and the second separator sheet.

TECHNICAL FIELD

The present invention relates to an electrode assembly manufacturing apparatus for preventing separator folding and an electrode assembly manufactured using the same. More particularly, the present invention relates to an electrode assembly manufacturing apparatus capable of forming a fine embossed pattern on a part of a separator sheet to be cut in the state in which the separator sheet is stretched tightly, thereby preventing folding of a separator, and an electrode assembly manufactured using the same.

BACKGROUND ART

Lithium secondary batteries, which are rechargeable and have high energy density, have attracted attention as a new energy source with environmentally-friendly characteristics not only because the lithium secondary batteries can drastically reduce the use of fossil fuels but also because the lithium secondary batteries do not generate by-products from the use of energy.

Lithium secondary batteries are in the limelight as an energy source for devices having high output and high energy density, such as electric vehicles, as well as wearable devices or portable devices.

A lithium secondary battery may be constituted by a battery cell configured to have a unit structure in which an electrode assembly constituted by a positive electrode and a negative electrode stacked in the state in which a separator is disposed therebetween is received in a battery case together with an electrolytic solution.

The electrode assembly includes a half-cell, which is configured to have a structure in which one electrode and two separators are stacked in the state in which the electrode is disposed between the separators, and a mono-cell, which is configured to have a structure in which two electrodes having different polarities are stacked in the state in which a separator is disposed at one side of each of the electrodes.

In order to manufacture the half-cell or the mono-cell, the two separators and the electrode are disposed so as to completely overlap each other in a stacking direction, and a lamination process of applying heat and pressure to the separators and the electrode so as to adhere to each other is performed.

In general, a separator is designed to have a larger area than electrodes in order to secure insulation between different polarities, and the separator may be folded or wrinkled during a transfer process for manufacturing an electrode assembly, whereby a defective electrode assembly may be manufactured. If a battery cell is manufactured using the defective electrode assembly, short circuit may occur between electrodes having different polarities.

Consequently, various attempts to prevent separator folding and to minimize occurrence of defective electrode assemblies have been made.

Korean Patent Application Publication No. 2017-0114351 (the “'351 publication”) relates to an electrode assembly manufacturing apparatus that performs a joining process in the state in which an electrode is aligned at a desired position. At the stage before the electrode is inserted into a joint, the electrode is fixed in position by a gripper, and the aligned electrode may be transferred to the joint by a guide roller, whereby it is possible to prevent misalignment of the electrode and the occurrence of steps.

However, the '351 publication does not disclose technology for preventing folding of a separator.

Korean Patent Application Publication No. 2021-0058170 (the “'170 publication”) relates to an electrode assembly manufacturing method and an electrode assembly manufacturing apparatus that compensate for the meander of an electrode, wherein the electrode assembly manufacturing method includes a meander correction process of transferring an electrode and a separator in an X-axis direction, which is a length direction of the electrode, and a Y-axis direction, which is a width direction of the electrode, in order to measure the center position of the electrode through a vision sensor and to move the positions of electrodes and a separator during electrode assembly manufacture, thereby compensating for position deviation.

The '170 publication discloses a method and apparatus for aligning the positions of the electrodes and the separator before a joining process of joining the electrodes and the separator; however, the '170 publication does not disclose technology for solving a problem, such as folding of the separator during electrode assembly transfer.

Therefore, there is a need for technology capable of preventing folding of a separator that is stacked on an electrode during manufacture of an electrode assembly, thereby preventing a defective electrode assembly from being manufactured during lamination.

DISCLOSURE

Technical Problem

The present invention has been made in view of the above problems, and it is an object of the present invention to provide an electrode assembly manufacturing apparatus capable of performing lamination in the state in which a separator of an electrode assembly is neither wrinkled nor folded, thereby preventing defects of the electrode assembly, and an electrode assembly manufactured using the same.

Technical Solution

An electrode assembly manufacturing apparatus according to the present invention to accomplish the above object includes a first separator supply unit configured to supply a first separator sheet from a first separator roll, a first electrode supply unit configured to cut a first electrode withdrawn from a first electrode roll and to supply a first unit electrode, a second separator supply unit configured to supply a second separator sheet from a second separator roll, an anti-wrinkle unit configured to hold the first separator sheet and the second separator sheet in order to apply tension thereto, a surface treatment unit configured to form a fine embossed pattern on each of the first separator sheet and the second separator sheet, a lamination unit configured to apply heat and pressure to the first separator sheet, the first unit electrode, and the second separator sheet so as to be attached to each other, and a cutting unit configured to cut the first separator sheet and the second separator sheet.

The electrode assembly manufacturing apparatus may further include a second electrode supply unit configured to cut a second electrode withdrawn from a second electrode roll and to supply a second unit electrode, wherein the lamination unit may apply pressure to the first separator sheet, the first unit electrode, the second separator sheet, and the second unit electrode so as to be attached to each other.

The surface treatment unit may be located in the anti-wrinkle unit.

The surface treatment unit may be disposed at a rear or trailing end of the anti-wrinkle unit.

The anti-wrinkle unit may include a pair of first grippers configured to hold opposite ends of the first separator sheet parallel to an advance or lengthwise direction and a pair of second grippers configured to hold opposite ends of the second separator sheet parallel to the advance direction, wherein the advance direction is the direction in which the first separator sheet, first electrode supply unit and second electrode sheet are transported along the electrode assembly manufacturing apparatus.

The pair of first grippers and the pair of second grippers may pull the opposite ends of the first separator sheet and the second separator sheet, respectively, such that the first separator sheet and the second separator sheet are stretched tightly so as to reduce or remove wrinkles or folds in the first and second separator sheets.

Each of the first grippers and the second grippers may be configured to have a structure in which a plurality of unit grippers is disposed on a circulation type transfer line, and the circulation type transfer line may transfer the plurality of unit grippers at the same speed as the transfer speed of each of the first separator sheet and the second separator sheet.

The plurality of unit grippers may be movable so as to individually approach the first separator sheet and the second separator sheet or to individually move away from the first separator sheet and the second separator sheet.

The surface treatment unit may include a first surface treatment unit configured to treat a surface of the first separator sheet and a second surface treatment unit configured to treat a surface of the second separator sheet,each of the first surface treatment unit and the second surface treatment unit may include a lower die and an upper punch, and a fine protrusion may be formed on the upper punch.

The surface treatment unit may form the fine embossed pattern on a part of each of the first separator sheet and the second separator sheet to be cut.

In the state in which the first separator sheet and the second separator sheet are disposed so as to be stacked, the fine embossed pattern formed on the first separator sheet and the fine embossed pattern formed on the second separator sheet may be disposed so as to overlap each other.

The present invention provides an electrode assembly manufactured using the electrode assembly manufacturing apparatus, wherein an outer periphery of each of a first separator and a second separator includes a surplus portion extending beyond an outer periphery of a first unit electrode, and a fine embossed pattern is formed on the surplus portion of each of the first separator and the second separator.

The electrode assembly may be a half-cell configured to have a structure in which a first separator, a first unit electrode, and a second separator are sequentially stacked or a mono-cell configured to have a structure in which a first separator, a first unit electrode, a second separator, and a second unit electrode are sequentially stacked.

In addition, the present invention may provide various combinations of the above constructions.

Advantageous Effects

As is apparent from the above description, in the present invention, lamination may be performed in the state in which a separator sheet is stretched tightly.

In addition, a fine embossed pattern is formed on the separator sheet, whereby it is possible to prevent slip between two separator sheets disposed so as to overlap each other.

BEST MODE

Now, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings such that the preferred embodiments of the present invention can be easily implemented by a person having ordinary skill in the art to which the present invention pertains. In describing the principle of operation of the preferred embodiments of the present invention in detail, however, a detailed description of known functions and configurations incorporated herein will be omitted when the same may obscure the subject matter of the present invention.

In addition, a description to embody elements through limitation or addition may be applied to all inventions, unless particularly restricted, and does not limit a specific invention.

Also, in the description of the invention and the claims of the present application, singular forms are intended to include plural forms unless mentioned otherwise.

Also, in the description of the invention and the claims of the present application, “or” includes “and” unless mentioned otherwise. Therefore, “including A or B” means three cases, namely, the case including A, the case including B, and the case including A and B.

FIG.1is a schematic view of an electrode assembly manufacturing apparatus according to the present invention.

Referring toFIG.1, the electrode assembly manufacturing apparatus according to the present invention includes a first separator supply unit100configured to supply a first separator sheet110from a first separator roll, a first electrode supply unit200configured to cut a first electrode210withdrawn from a first electrode roll and to supply a first unit electrode211, a second separator supply unit300configured to supply a second separator sheet310from a second separator roll, an anti-wrinkle unit500configured to hold the first separator sheet110and the second separator sheet310in order to apply tension thereto, a surface treatment unit600configured to form a fine embossed pattern on each of the first separator sheet110and the second separator sheet310, a lamination unit700configured to apply heat and pressure to the first separator sheet110, the first unit electrode211, and the second separator sheet310so as to be attached to each other, and a cutting unit800configured to cut the first separator sheet110and the second separator sheet310.

The first separator sheet110, the first unit electrode211, and the second separator sheet310supplied respectively from the first separator supply unit100, the first electrode supply unit200, and the second separator supply unit300may be thermally bonded, and the first separator sheet110and the second separator sheet310may be cut by the cutting unit800, whereby it is possible to manufacture a half-cell type electrode assembly.

Additionally, the electrode assembly manufacturing apparatus according to the present invention may further include a second electrode supply unit400configured to cut a second electrode410withdrawn from a second electrode roll and to supply a second unit electrode411. The lamination unit700may apply pressure to the first separator sheet110, the first unit electrode211, the second separator sheet310, and the second unit electrode411so as to be attached to each other, whereby it is possible to manufacture a mono-cell type electrode assembly.

That is, in the present invention, the anti-wrinkle unit500is provided in order to, when an electrode assembly including at least two separator sheets is manufactured, prevent the separator sheets from being folded or from being wrinkled.

Also, in order to increase the force of friction between two or more separator sheets that face each other, thereby preventing slip of the separator sheets during a transfer process, the surface treatment unit600is included, which is configured to form a fine embossed pattern on each of surfaces of the separator sheets that face each other.

In order to prevent each of the first separator sheet110and the second separator sheet310from being wrinkled, the anti-wrinkle unit500pulls the outer periphery of each of the first separator sheet110and the second separator sheet310such that each of the first separator sheet and the second separator sheet is stretched tightly.

The anti-wrinkle unit500is disposed at a front end of the lamination unit700, whereby it is possible to prevent the separator sheet from being wrinkled before a stack constituted by the separator sheets and the electrode enters the lamination unit700. When the lamination unit700applies heat and pressure to the stack constituted by the separator sheets and the electrode, therefore, the electrode and the separator sheets may be attached to each other in a flat state.

When the electrode assembly manufacturing apparatus according to the present invention is used, as described above, it is possible to prevent the separators from being folded or wrinkled, and therefore it is possible to solve a problem in that contact between electrodes having different polarities occurs due to poor attachment of the separators.

In a concrete example, when the surface treatment unit600is located in the anti-wrinkle unit500, a process of forming a fine embossed pattern on an outer surface of each of the first separator sheet110and the second separator sheet310in the state in which each of the first separator sheet110and the second separator sheet310is stretched tightly may be performed.

Alternatively, the surface treatment unit600may be disposed at a rear or trailing end of the anti-wrinkle unit500. When the first separator sheet110and the second separator sheet310stretched tightly by the anti-wrinkle unit500are moved to the surface treatment unit600, the surface treatment unit600may form a fine embossed pattern on each of the first separator sheet110and the second separator sheet310.

FIG.2is a plan view showing the state in which the anti-wrinkle unit according to the present invention holds a separator sheet,FIG.3is a perspective view ofFIG.2, andFIG.4is a side view of the anti-wrinkle unit according to the present invention.FIGS.2and3show one separator sheet and an anti-wrinkle unit configured to hold the one separator sheet; however, the one separator sheet includes the first separator sheet110and the second separator sheet310. Consequently, a description of the first separator sheet110given with reference toFIGS.2and3may be equally applied to the second separator sheet.

In addition,FIGS.2to4show only a first gripper510configured to hold the first separator sheet; however, the following description of the first gripper510configured to hold the first separator sheet110may be equally applied to a second gripper configured to hold the second separator sheet310.

Referring toFIGS.2to4, the anti-wrinkle unit500according to the present invention includes a pair of first grippers510configured to hold opposite ends of the first separator sheet110parallel to an advance of lengthwise direction A and a pair of second grippers configured to hold opposite ends of the second separator sheet parallel to the advance direction.

Although the second grippers are not shown in the figures, the second separator sheet and the second grippers configured to hold the second separator sheet may be disposed above the first separator sheet110and the first grippers510configured to hold the first separator sheet.

First unit electrodes211are disposed on an upper surface of the first separator sheet110at regular intervals in the advance direction A. Surplus portions extending more than opposite ends of each of the first unit electrodes211are located at opposite ends of the first separator sheet110parallel to the advance direction A, and the first grippers510hold the surplus portions.

Consequently, it is possible to prevent the first unit electrodes211from being damaged by the first grippers510configured to hold the first separator sheet110.

The first grippers510and the second grippers pull opposite ends of the first separator sheet110and the second separator sheet310, respectively, such that the first separator sheet110and the second separator sheet310are stretched tightly. That is, the pair of first grippers510pulls the first separator sheet110in a direction in which the distance therebetween is increased such that the first separator sheet110is stretched tightly.

FIGS.2to4show the structure in which16pairs of first grippers510are disposed on a circulation type transfer line520in the advance direction A of the first separator sheet110; however, the number of pairs of first grippers disposed on the circulation type transfer line520is not limited thereto.

The circulation type transfer line520is located at each of the opposite ends of the first separator sheet110parallel to the advance direction A, and a plurality of unit grippers511is disposed on each circulation type transfer line520at regular intervals.

The circulation type transfer line520transfers the plurality of unit grippers511while moving at the same speed as the transfer speed of each of the first separator sheet110and the second separator sheet310.

FIG.5is a front view of the anti-wrinkle unit according to the present invention.

Referring toFIG.5, each of the plurality of unit grippers511may include an upper unit and a lower unit. One end of the upper unit and one end of the lower unit may function as a kind of axis of rotation in a state of being coupled to each other, and the other end of the upper unit and the other end of the lower unit may be deformed about the axis of rotation such that an open state and a closed state are repeated.

Specifically, the plurality of unit grippers511may move along the circulation type transfer line520in the state in which the upper unit and the lower unit are opened, as shown in an upper part ofFIG.5. When the plurality of unit grippers reaches the first separator sheet110, the plurality of unit grippers may be deformed into a closed state in order to hold opposite ends of the first separator sheet110parallel to the advance direction A, whereby pulling force, i.e. tension, may be applied to the first separator sheet110, as shown in a lower part ofFIG.5.

When the process in which the plurality of unit grippers511pulls the separator sheet while moving along the circulation type transfer line520is finished, the plurality of unit grippers releases the first separator sheet110and is deformed into the shape shown in the upper part ofFIG.5.

In addition, when the plurality of unit grippers511approaches the separator sheet while moving along the circulation type transfer line520, the plurality of unit grippers moves closer to the separator sheet, and the open state of the unit grippers is changed to the closed state of the unit grippers to hold the surplus portions of the outer periphery of the separator sheet. Subsequently, the separator sheet is pulled such that the distance between the opposite ends of the separator sheet is increased in order to tightly stretch the separator sheet. When the process of pulling the separator sheet is finished, the closed state of the unit grippers may be changed to the open state of the unit grippers, and the unit grippers may move farther away from the separator sheet.

That is, in order to tightly stretch all separator sheets that continuously move using the plurality of unit grippers, the plurality of unit grippers511may move closer to or farther away from the separator sheet.

FIG.6is a plan view of a separator sheet having a fine embossed pattern formed thereon, andFIG.7is a perspective view of the surface treatment unit.

FIG.6shows one separator sheet and electrodes disposed thereon at regular intervals; however, the separator sheet shown inFIG.6includes the first separator sheet and the second separator sheet.

FIG.7shows two kinds of surface treatment units, wherein the surface treatment units include a first surface treatment unit configured to treat a surface of the first separator sheet and a second surface treatment unit configured to treat a surface of the second separator sheet, and the surface treatment units shown inFIG.7may be applied as the first surface treatment unit and the second surface treatment unit.

Referring toFIGS.6and7, each of the first surface treatment unit and the second surface treatment unit includes a lower die620and an upper punch610, wherein fine protrusions611are formed on a lower surface of the upper punch610.

The shape of the fine protrusion611is not particularly restricted as long as a fine embossed pattern can be formed on a surface of the separator sheet when the separator sheet is pressed. For example, the fine protrusions may be formed in any of various shapes, such as a straight shape, a curved shape, a hemispherical shape, a cylindrical shape, a prismatic shape, etc. and may be formed on the entirety or a part of the lower surface of the upper punch.

Meanwhile, an upper surface621of the lower die620is flat. Consequently, a fine embossed pattern601may be formed on the upper surface of the first separator sheet110pressed by the upper punch having the fine protrusions611formed thereon, whereas no fine embossed pattern may be formed on a lower surface of the first separator sheet that faces the lower die, i.e. the lower surface of the first separator sheet may be flat.

In the state in which the first separator sheet110and the second separator sheet are disposed so as to be stacked, the fine embossed pattern601formed on the first separator sheet110and the fine embossed pattern601formed on the second separator sheet may be disposed so as to overlap each other.

In addition, the parts of the first separator sheet110and the second separator sheet310on each of which the fine embossed pattern601is formed by the surface treatment unit may be the parts of the first separator sheet and the second separator sheet that are cut. When the embossed pattern601is formed such that the middle of the embossed pattern601is disposed on a cutting line630, a cut first separator111(FIG.1) and a cut second separator311(FIG.1) may remain attached to each other due to frictional force generated by the fine embossed pattern601when the first separator sheet110and the second separator sheet310are cut.

The electrode assembly manufactured using the electrode assembly manufacturing apparatus may be a half-cell, which is configured to have a structure in which a first separator, a first unit electrode, and a second separator are sequentially stacked, or a mono-cell, which is configured to have a structure in which a first separator, a first unit electrode, a second separator, and a second unit electrode are sequentially stacked. The first unit electrode and the second unit electrode may be a positive electrode and a negative electrode, respectively, or a negative electrode and a positive electrode, respectively.

In the electrode assembly, an outer periphery of each of the first separator and the second separator may include a surplus portion extending more than an outer periphery of the first unit electrode, and a fine embossed pattern may be formed on the surplus portion of each of the first separator and the second separator. That is, the fine embossed pattern may be formed on opposite side outer peripheries of the first separator and the second separator parallel to each other, among the outer peripheries of the first separator and the second separator, and friction between the separators may be increased by the fine embossed pattern formed on the surplus portions.

Consequently, it is possible to prevent the surplus portion of the separator from being folded in the process of transferring the electrode assembly, the process of stacking components of the electrode assembly, and the process of injecting an electrolytic solution in order to receive the electrode assembly in a battery case and to manufacture a battery cell.

Those skilled in the art to which the present invention pertains will appreciate that various applications and modifications are possible within the category of the present invention based on the above description.

DESCRIPTION OF REFERENCE NUMERALS