METHODS AND SYSTEMS FOR ENCAPSULATING BATTERY ELECTRODES

A system for encapsulating electrodes for a battery includes lower path rollers, a conveyor frame, conveyor drives, a continuous track, and a heat press. The lower path rollers are operable to guide a first web of separator material along a lower web path. The conveyor frame supports the lower path rollers. The conveyor drives are supported on the conveyor frame. The continuous track is driven by the conveyor drives and is positioned beneath the lower web path. The continuous track includes conveyor magnets embedded within pallets. The magnets are operable to secure electrode material against the first web. The heat press is positioned above the continuous track and includes a heated surface configured to heat and press a second web of separator material against the first web to encapsulate at least a portion of the electrode material within the first web and the second web.

BACKGROUND

Electric vehicles increasingly use pouch-type batteries. Pouch batteries wrap the electrodes (anode and cathode), separator, and electrolyte in a pouch film to create a mono-cell. Multiple mono-cells are then stacked and added to other components to form a battery or battery cell. Electrode production involves cutting electrode materials using a press. The scrap electrode materials must be manually removed from the electrodes to avoid damaging the electrodes. The electrodes are then placed in a stacked arrangement with separator material positioned between the cathode and anode. This process is labor intensive and contains multiple pinch points that reduce efficiency and production rates.

SUMMARY OF THE INVENTION

The present invention solves the above-described problems and other problems by providing systems and methods for encapsulating electrodes and assembling battery electrodes that enable automation and increased production rates.

A system constructed according to an embodiment of the present invention encapsulates electrodes for a battery. The system includes lower path rollers, a conveyor frame, conveyor drives, a continuous track, and a heat press. The lower path rollers are operable to guide a first web of separator material along a lower web path. The conveyor frame supports the lower path rollers. The conveyor drives are supported on the conveyor frame. The continuous track is driven by the conveyor drives and is positioned beneath the lower web path. The continuous track includes conveyor magnets embedded within pallets. The magnets are operable to secure electrode material against the first web.

The heat press is positioned above the continuous track and includes a heated surface configured to heat and press a second web of separator material against the first web to encapsulate at least a portion of the electrode material within the first web and the second web. The magnets of the continuous track enable the electrode material to be conveyed on separator material. This enables the use of an automated heat press to quickly seal the electrode material in a second web of separator material, thereby producing an electrode capable of integration into a battery, such as a pouch battery.

A method of encapsulating an electrode of a battery includes guiding a first web of separator material onto a magnetic conveyor system. The magnetic conveyor system includes connected pallets forming a continuous track. The pallets have conveyor magnets embedded therein that are operable to secure electrode material against the first web. The method further includes positioning the electrode material onto the first web located on the magnetic conveyor system; guiding a second web of separator material onto the electrode material; shifting, via the magnetic conveyor system, the electrode material positioned between the first web and the second web to a location beneath a heat press; and heating, via the heat press, the first web and the second web around the electrode material, thereby encapsulating the electrode material.

Another embodiment of the present invention is a magnetic conveyor for transporting electrode material of a battery. The magnetic conveyor includes a conveyor frame, conveyor drives, and a continuous track. The conveyor drives are supported on the conveyor frame. The continuous track is driven by the conveyor drives and includes pallets having one or more magnets embedded therein for securing the electrode material in association with the continuous track.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Turning toFIG.1, a system10constructed in accordance with an embodiment of the invention is illustrated. The system10is configured to encapsulate electrodes12A,12B (anodes12A and cathodes12B) with separator material using two webs14,16from one or more rolls of separator material and place the encapsulated electrodes12A,12B in a receiver18(depicted inFIG.4). The electrodes12A,12B may be made of any type of cathode or anode material known in the art without departing from the scope of the present invention. As shown inFIG.2, the cathode12B may include one or more tabs20. Similarly, as shown inFIG.3, the anode12A may also include one or more tabs22,24. The tab20may be located on the cathode12B so that it is aligned with the space between the tabs22,24of the anode12A when the cathode12B and anode12A are stacked on top of each other. The separator material may comprise any separator material known in the art for separating cathodes and anodes, such as nonwoven fibers, polymer films, or the like.

Turning back toFIG.1, an embodiment of the system10comprises a separator material unwinder26, a window press28, a magnetic conveyor30, one or more electrode forming systems32,34,36, a heat press38, a tab forming press40, a knockout station42, and a scrap rewind station44. Turning toFIG.5, the unwinder26comprises one or more rollers46,48for supporting and unwinding rolls50,52of material. The bottom roller46supports and/or helps unwind the bottom web14from the lower roll of separator material50. The upper roller48supports and/or helps unwind the upper web16from the upper roll of separator material52. In one or more embodiments, the unwinder26includes one or more guide rollers54and/or tensioner rollers56for maintaining the tension in the webs14,16.

Turning toFIG.6, the window press28receives the webs14,16from the unwinder26and is operable to form one or more perforations in the webs14,16in the same action. The press28includes one or more cutting tools58,59for forming the perforations. In one or more embodiments, the tools58,59include edges or blades for cutting out windows60(depicted as dotted lines inFIG.9) in the webs14,16corresponding to locations of the tabs20,22,24when the electrodes12A,12B are positioned on the lower web14. The windows60create gaps in the pouch and expose the tabs20,22,24on the electrodes for connection into a cell later in the manufacturing process.

In one or more embodiments, the tools58,59also include edges or blades for forming perforations representing the outline62(also depicted as dotted lines inFIG.9) of the separator material knocked out with the electrodes12A,12B, as discussed in more detail below. The press28may be configured to operate so that the upper tool58is actuated downwards so that the webs14,16are pressed between the upper tool58and lower tool59, thereby forming the perforations in the webs14,16in the same action, or simultaneously. Once the perforations are formed, one or more lower path rollers64direct the perforated lower web14along a lower web path to the magnetic conveyor30, and one or more upper path rollers66direct the perforated upper web16along an upper web path to the magnetic conveyor30.

Turning toFIG.7, the magnetic conveyor30helps transport electrodes12A,B on the lower web14to the heat press38and then transports the electrodes12A,B encapsulated in the webs14,16to the tab forming press40. The conveyor30includes a frame68, one or more conveyor drives70, and a continuous track72. The frame68may operatively support the conveyor drives70, the lower path rollers64, and the upper path rollers66. Turning toFIG.8, the lower path rollers64define a lower path for the lower web14extending along the top of the continuous track72so that electrodes12A,B may be placed directly on the top surface of the lower web14. The upper path rollers66define an upper path above continuous track72and spaced apart from the lower path to define electrode material handling spaces74,76. Downstream from the electrode material handling spaces74,76, one or more of the upper path rollers66include phase adjuster rollers67that direct the upper web16down onto the electrodes12A, B positioned on the lower web14so that the heat press38can encapsulate at least portions of the electrodes12A,B in the webs14,16with the electrodes12A, B sandwiched between the webs14,16. The system10may include a vertically actuatable phase adjuster69configured to correct any different path length between the upper and lower webs14,16.FIG.9depicts the electrodes12A, B positioned on a section of the lower web14with the dotted lines representing portions of the webs14,16to be cut and knocked out.

Turning toFIG.10, the conveyor drives may comprise a drive sprocket78, one or more support sprockets80, a guide sprocket82, and one or more motors84for driving the drive sprocket78. The sprockets78,80,82may be secured to axles that are rotatably mounted on the conveyor frame via bearings or the like. The sprockets78,80,82include teeth configured to engage one or more links of the chains (discussed below) of the continuous track72. The motor84may comprise a servo motor that drives the drive sprocket78, which causes the chains to travel in a continuous path supported by the support and guide sprockets80,82.

The continuous track72comprises two or more chains86and a plurality of pallets88connected to the chains86. As discussed above, the chains86are engaged by the sprockets78,80,82so that the chains86rotate about the sprockets78,80,82, thereby shifting the connected pallets88with the chains86. The pallets88may be attached to the chains86in accordance with a desired center-to-center distance between electrodes12A, B.

Turning toFIG.11, an exemplary pallet88is depicted and comprises a base90, a plurality of magnets92, and a cover94. The base90includes a plurality of cavities96for receiving the magnets92. Embodiments of the invention may include various types of magnets92without departing from the scope of the present invention. Such types may include, but are not limited to, permanent magnets such as neodymium iron boron (NdFeB), samarium cobalt (SmCo), alnico, and ferrite or ceramic magnets; temporary magnets such as soft iron magnets; and electromagnets, which can be further subdivided into categories such as iron core, air core, toroidal, and horseshoe electromagnets. In preferred embodiments, the magnets92comprise permanent magnets rather than electromagnets as some types of electrode material have insufficient ferrous mass to complete a magnetic field required for an electromagnet to generate a sufficient attractive force to maintain the electrodes on the web14. Permanent magnets have an intrinsic magnetic field and are capable of producing an attractive force on thin materials that may have limited ferrous material. In such embodiments, the magnets92comprise rare-earth magnets, such as NdFeB or SmCo magnets. The magnets92are placed in the cavities96, and the cover94is secured to the base90to hold the magnets92in the base90.

In one or more embodiments, the pallets88include one or more registration marks89. A sensor, such as a camera91(depicted inFIG.8), may be placed on the conveyor frame68for detecting the registrations marks89of the pallets88to control advancement of the conveyor30.

Turning briefly back toFIG.1, the electrode forming systems32,34,36include one or more material feeds98,100,102for providing sheets104,106,108of electrode material to their respective electrode cutting modules110,112,114. The material feeds98,100,102may include any material handling tools known in the art for providing the sheets104,106,108to the cutting modules110,112,114, including conveyor systems, cartridges, pinch rollers, etc. The cutting modules110,112,114are configured to receive their respective sheets104,106,108and cut from the sheets electrodes12A, B and then place the electrodes12A, B onto the conveyor30through the electrode material handling spaces74,76. While the system10is depicted as including one anode forming system32and two cathode forming systems34,36, the system10may include any number or combination of such electrode forming systems without departing from the scope of the present invention. The number of electrode forming systems of a particular type may depend on the type or thickness of material used to form the electrode.

Turning toFIG.12, an exemplary cathode cutting module112is depicted. The cathode cutting module112may be substantially similar to the other cathode cutting module114. The cathode cutting module112comprises a frame116, one or more external feed rollers118, one or more internal feed rollers120, a first tool122for forming lateral sides of the electrodes (as best depicted inFIGS.20-22), a second tool124for forming longitudinal sides of the electrodes (as depicted inFIGS.20-22), a magnetic clamp hitch feed126(depicted inFIG.13), a stationary clamp assembly128(depicted inFIG.13), and a pick-and-place assembly130. The frame116is positioned next to the magnetic conveyor30and supports the external feed rollers118, the internal feed rollers120, the first and second tools122,124, the magnetic clamp hitch feed126, the stationary clamp assembly128, and the pick-and-place assembly130.

Turning toFIG.13, the module112is depicted with upper portions of the tools122,124removed to illustrate the two cutting stages of the module112. The external feed rollers118are operable to receive a sheet106of cathode material and pull it into a first cutting area132. The external feed rollers118may include a pair of nip or pinch rollers and a motor. Similarly, the internal feed rollers120may include a pair of nip or pinch rollers and a motor. The internal feed rollers120are operable to receive a portion of the sheet106and help position the sheet106for the first stage of cutting by the first tool122(discussed in more detail below), which forms slits in the sheet106that will define the lateral sides of the cathode12B, including the tabs20. One end of the sheet106may be positioned in the first area132and the other end may be positioned in the second cutting area134when the lateral sides are being cut. Once the lateral sides of the cathode12B are formed, the feed rollers118,120cooperatively position the perforated sheet106into the second area134for cutting the longitudinal sides of the cathode12B using the second tool124, as discussed in more detail below.

Turning toFIG.20, the first and second tools122,124are depicted in isolation from the rest of the module112. In one or more embodiments, the first tool122is a match metal tool with a first punch assembly136and a second punch assembly138. The first punch assembly136is positioned on a first side of the internal feed rollers120, or in the first cutting area132. In one or more embodiments, the first punch assembly136includes an upper tool or punch140and a complementary lower die plate142that cooperatively form the lateral sides and tabs in the cathodes12B. The punch140includes one or more edges144or blades operable to form the tabs20in the cathodes12B.

Turning toFIG.21, the second punch assembly138is spaced apart from the first punch assembly136and located on a second side of the internal feed rollers120, or in the second cutting area134. In one or more embodiments, the second punch assembly138includes an upper tool or punch146and a complementary lower die plate148that cooperatively form the lateral sides in the cathodes12B opposite the tabs. The upper punch146includes one or more punches or knives150(depicted inFIG.22) for cutting the sheet106and forming the other lateral sides (or chamfered ends) of the cathodes12B. The upper punch146may be integrally formed with an upper punch of the second tool124so that the upper punch146of the first tool122forms lateral sides in a second sheet while the second tool124simultaneously forms longitudinal sides in a first sheet, as depicted inFIG.21. However, the upper punch146may be independent from the second tool124. Additionally, in one or more embodiments, the first and second assemblies136,138may be positioned on either side of the internal feed rollers120.

The second tool124includes a lower die152and an upper punch154. The lower die152includes a plurality of spaced apart steel rule cutting blocks156. The cutting blocks156include cutting surfaces158for supporting the perforated sheet of electrode material and against which portions of the upper punch154pinch the electrode material to form the longitudinal sides of the cathodes. The cutting blocks156are spaced apart from one another to define channels160. Turning toFIG.22, the upper punch154is positioned above the cutting surfaces158and is operable to be actuated to cut the perforated sheet of electrode material against the steel rule cutting surfaces158to form the longitudinal sides of the cathodes12B and thereby cut the cathodes12B from the sheet106. The upper punch154of the second tool124includes cutting edges162corresponding to and vertically aligned with the cutting surfaces158.

The tools122,124may be actuated using any actuator known in the art, including, but not limited to, linear actuators, motors, hydraulic actuators, pneumatic actuators, or the like. As depicted, the module112is an underdrive configuration and the ram113(depicted inFIG.12) and therefore the tools122,124are driven up and down by a hydraulic cylinder mounted below the bottom plate115of the press. This prevents any hydraulic leaks from contaminating the electrode material. Hydraulic power units for the cathode module112may be remotely located in an area away from the module112. Various adjustments located on the press allow variation of the press tonnage. The down position of the ram113may be controlled by powered depth stops, and the up limit of the ram113may be programmable from the human-machine interface. The tools122,124may be mounted on linear rails to allow the tools122,124to be positioned correctly relative to the stopping points of the conveyor30as a set up variable. One or more clamp brackets may be used to lock the tools122,124to the non-moving portions of the frame116once the correct position of the tools122,124has been determined. In one or more embodiments, the tools122,124comprise match metal dies that are punch through dies, thereby enabling the operator to adjust the ram depth for the precise positioning required by the steel rule die162cutting against the cutting plate surfaces of the steel rule cutting blocks156.

Turning toFIG.14, once the cathodes12B are cut from the sheet106, the magnetic clamp hitch feed126shifts the cathodes12B onto the stationary clamp assembly128. The magnetic clamp hitch feed126includes a track164, a motor plate166, actuators168,170, and magnetic clamp assemblies172. The track164is supported on the module frame116, and the motor plate166supports the magnetic clamp assemblies172and is shiftable along the track164. The actuators168,170are linear actuators or motors configured to shift the motor plate166along the track164. The magnetic clamp assemblies172are shiftable within the channels160and comprise a top surface174for supporting the cathode sheet/cathodes12B and one or more clamp magnets176for engaging the cathode sheet/cathodes12B. Similar to the magnets92of the conveyor30, the clamp magnets176may include various types of magnets without departing from the scope of the present invention, and in preferred embodiments, comprise rare-earth magnets.

Turning toFIG.15, the magnetic clamp assemblies172are connected to the motor plate166via pistons178. The assemblies172may include shiftable rods180extending into and shiftable relative to the pistons178. A pressure source182(hydraulic or pneumatic) is operable to shift the rods180to shift the assemblies172relative to the top surfaces158of the cutting blocks. The magnetic clamp assemblies172may be configured to be shifted downward below the top surfaces158of the cutting blocks to release the hold of the clamp magnets176on the cathode sheet/cathodes. Specifically, the magnetic clamp assemblies172are operable to engage the perforated sheet of cathode material, hold the sheet until the cathodes12B are cut from the sheet, shift toward the stationary clamp assembly128, and shift downwards to release the cathodes12B onto the stationary clamp assembly128. WhileFIG.15depicts the magnetic clamp assemblies172being shiftable relative to the top surfaces158via pistons178, the assemblies may be shiftable through other means without departing from the scope of the present invention. For example, they may be shiftable via one or more other types of actuators, such linear motors. When the magnetic clamp hitch feed126moves the perforated electrode material sheet into position, it simultaneously moves the previous cycle's completed cathodes into the load area by means of the strategically located magnets177located on the other side of the top surface174of the clamp assemblies relative to magnets176.

The stationary clamp assembly128is positioned between the conveyor30and the top surfaces158of the cutting blocks. The stationary clamp assembly128includes a staging plate184and shiftable magnetic clamps186. The staging plate184may be directly or indirectly supported by the module frame. The magnetic clamps186are vertically shiftable relative to the top surface185of the staging plate184and include pistons188, support plates190, and one or more staging magnets192. The pistons188are shiftably connected to rods194that are in fixed relationships with the module frame and/or the staging plate184. The support plates190are connected to the pistons188, and the magnets192are secured to the support plates190. The staging plate184may include one or more cavities through which at least portions of the staging magnets192extend. The stationary clamp assembly128receives the cathodes12B from the magnetic clamp assembly126, and the staging magnets192secure the cathodes12B until the pick-and-place assembly130pulls the cathodes12B from the staging plate184and transports the cathodes to the conveyor30.

Turning briefly back toFIG.12, the pick-and-place assembly130is configured to engage the cathodes12B from the stationary clamp assembly128and place them on the conveyor30. The assembly130may include one or more tracks196,198along different axes, one or more linear actuators or motors200,202,204, and one or more pick heads206. The linear actuator204shifts the pick head206vertically, or along a z-axis, to pick up and release cathodes12B. The motor202shifts the linear actuator204and therefore the pick head206along the x-axis track198, and the motor200shifts the x-axis track198(and therefore the pick head206) along the y-axis track196. The pick head206may comprise any type of pick head known in the art, including, but not limited to, a vacuum pick head. As depicted inFIG.12, the pick head206comprises a vacuum pick head for use when, for example, the cathode material is non-porous. In one or more embodiments, the pick head206may alternatively include a magnetic component, similar to the pick head of the anode module110discussed below. The cathode cutting module112may further include one or more outboard sensors, such as cameras131, configured to measure pallet registration mark89positions and determine the electrode placement position allowing for a higher placement accuracy than the pallet registration sensor91alone. The cathode cutting module112may further include one or more inboard sensors, such as cameras133, configured to view the electrodes in the load position, or on the staging plate184. Once in the loading area, the inboard cameras133determine the precise positions of cathodes, and the outboard cameras131determine the precise pallet positions. This allows controllers to determine the required move to place the electrodes correctly on the pallet.

The cathode cutting module114may be substantially similar to the cathode cutting module112. The pick-and-place assembly of the second cathode cutting module114is configured to stack its cathodes12B on top of the cathodes12B placed on the conveyor30by the first cathode cutting module112. The extra layer of cathode material to form the final cathode product improves the performance of the battery.

Turning toFIG.16, the anode cutting module110is substantially similar to the cathode cutting module112except that the tooling is configured to shape the anodes12A, and the pick heads208,210include magnets. In one or more embodiments, the anode material comprises several layers of nickel mesh welded together, presenting a thicker, yet porous material. Thus, in one or more embodiments, the tools of the anode cutting module110are configured to form the two tabs22,24of the anodes12A and include a steel rule die to form the notched or chamfered lateral sides of the anodes instead of a match metal die. Further, in one or more embodiments, the magnetic fields of the pick head magnets engage the anodes instead of a vacuum pick head. Turning toFIG.17, an exemplary pair of anode pick heads208,210are depicted. The pick heads208,210may be secured to the pick-and-place assembly via a support plate212. Turning toFIG.18, the pick heads208,210include body cylinders214,216, outer pistons218,220, inner pistons222,224, and pick head magnets226,228.

The body cylinders214,216are operatively associated with the actuator via the support plate212. The support plate212may be sized to hold the pick heads208,210at a distance to prevent them from coinciding with the magnets on the pallets of the conveyor. The outer pistons218,220are positioned in the body cylinders214,216and are operable to shift relative to the body cylinders214,216due to pressure differentials applied at the outer piston air sources230,232. The outer pistons218,220define chambers within which the inner pistons222,224shift. The inner pistons222,224are positioned in the chambers and are operable to shift relative to their respective outer pistons218,220due to pressure differentials applied at the inner piston air sources234,236. While the pick heads208,210are described as being pneumatic, they may alternatively be hydraulic or electrically actuated without departing from the scope of the present invention. The pick head magnets226,228are attached to the inner pistons222,224are operable to magnetically attract the anodes12A and hold the anodes12A when in the extended position depicted inFIG.18. When the pick heads208,210are positioned over the lower web14on the conveyor30, the inner pistons222,224are configured to retract the pick head magnets226,228into the magnet chambers238,240defined by the outer pistons218,220. The top surfaces of the anodes12A then abut the bottom ends of the outer pistons218,220, while the inner pistons222,224pull the magnets226,228away from the anodes12A. The anodes12A are distanced from the magnetic field of the magnets226,228, thereby reducing the attractive forces and releasing the anodes12A onto the lower web14on the conveyor30.

Turning toFIG.19, once the electrodes12A, B have been placed on the lower web14on the conveyor30, the phase adjuster rollers67direct the upper web16down onto the electrodes12A, B. The heat press38applies a heated edge or surface around the electrodes12A, B (the dotted lines inFIG.9) thereby encapsulating at least a portion of the electrodes12A, B in the webs14,16. The heat press38may also include one or more cutting edges for forming perforations in the webs14,16around the electrodes12A, B to aid in removing the encapsulated electrodes from the webs14,16. The tab forming press40is a vertically-actuating press with protrusions positioned to contact and bend the tabs of the electrodes to predefined angles relative to the remainder of their electrode bodies. The scrap rewind station44includes one or more scrap rollers242that help pull the webs14,16with the electrodes12A, B encapsulated therein off the magnetic conveyor30toward the knockout station42. The receiver18is movably positioned on a track244and shifted by an actuator246, such as a servo motor. The knockout station42includes a punch248that is actuated to push out one of the electrodes12A, B at a time while the actuator246shifts the receiver18to receive the knocked-out electrode. The receiver18is actuated back and forth along the track244so that it alternates between receiving anodes12A and cathodes12B. This results in the anodes12A and cathodes12B being stacked in an alternating order within the receiver18. The scrap roller242winds up the scrap separator material of the webs14,16.

While the system10is described as being configured to produce both anodes12A and cathodes12B, the system10may be configured to produce only one type of electrode without departing from the scope of the present invention. For example, the cathode forming systems34,36may replace the anode forming system32or vice versa, and the knockout station42may place the knocked-out electrodes of a single type in a container for offline installation in a battery or on a conveyor system.

Turning toFIG.23, an exemplary control architecture of the system10is depicted. The system10may include one or more controller250in wired or wireless communication with the motor controllers, sensors, valves, and pumps of the separator material unwinder26, the window press28, the magnetic conveyor30, the electrode forming systems32,34,36, the heat press38, the tab forming press40, the knockout station42, and the scrap rewind station44. Various components of the system10may be controlled by and/or in communication with the controller250. The controller250may comprise a communication element, a memory element, a human-machine interface, and one or more processing element. The communication element may generally allow communication with systems or devices within and/or external to the system10. The communication element may include signal or data transmitting and receiving circuits, such as antennas, amplifiers, filters, mixers, oscillators, digital signal processors (DSPs), and the like. The communication element may establish communication wirelessly by utilizing RF signals and/or data that comply with communication standards such as cellular 2G, 3G, 4G, 5G, or LTE, WiFi, WiMAX, Bluetooth®, BLE, or combinations thereof. The communication element may be in communication with the processing element and the memory element.

The memory element may include data storage components, such as read-only memory (ROM), programmable ROM, erasable programmable ROM, random-access memory (RAM) such as static RAM (SRAM) or dynamic RAM (DRAM), cache memory, hard disks, floppy disks, optical disks, flash memory, thumb drives, universal serial bus (USB) drives, or the like, or combinations thereof. In some embodiments, the memory element may be embedded in, or packaged in the same package as, the processing element. The memory element may include, or may constitute, a “computer-readable medium”. The memory element may store the instructions, code, code segments, software, firmware, programs, applications, apps, services, daemons, or the like that are executed by the processing element.

The user interface generally allows the user to utilize inputs and outputs to interact with the system10and is in communication with the processing element. Inputs may include buttons, pushbuttons, knobs, jog dials, shuttle dials, directional pads, multidirectional buttons, switches, keypads, keyboards, mice, joysticks, microphones, or the like, or combinations thereof. The outputs of the present invention may include a display or any number of additional outputs, such as audio speakers, lights, dials, meters, printers, or the like, or combinations thereof, without departing from the scope of the present invention.

The processing element may include processors, microprocessors (single-core and multi-core), microcontrollers, DSPs, field-programmable gate arrays (FPGAs), analog and/or digital application-specific integrated circuits (ASICs), or the like, or combinations thereof. The processing element may generally execute, process, or run instructions, code, code segments, software, firmware, programs, applications, apps, processes, services, daemons, or the like. The processing element may also include hardware components such as finite-state machines, sequential and combinational logic, and other electronic circuits that can perform the functions necessary for the operation of the current invention. The processing element may be in communication with the other electronic components through serial or parallel links that include address buses, data buses, control lines, and the like.

The flow chart ofFIG.24depicts the steps of an exemplary method1000of encapsulating one or more electrode of a battery. In some alternative implementations, the functions noted in the various blocks may occur out of the order depicted inFIG.24. For example, two blocks shown in succession inFIG.24may in fact be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order depending upon the functionality involved. In addition, some steps may be optional.

The method1000is described below, for ease of reference, as being executed by exemplary devices and components introduced with the embodiments illustrated inFIGS.1-23. The steps of the method1000may be performed by the controller250through the utilization of processors, transceivers, hardware, software, firmware, or combinations thereof. However, some of such actions may be distributed differently among such devices or other devices without departing from the spirit of the present invention. Control of the system may also be partially implemented with computer programs stored on one or more computer-readable medium(s). The computer-readable medium(s) may include one or more executable programs stored thereon, wherein the program(s) instruct one or more processing elements to perform all or certain of the steps outlined herein. The program(s) stored on the computer-readable medium(s) may instruct processing element(s) to perform additional, fewer, or alternative actions, including those discussed elsewhere herein.

Referring to step1001, the first and second webs are unwound from rolls of separator material and guided to the conveyor. In one or more embodiments, this step also includes forming tab windows and/or perforations in the webs via the window press. The second web may be directed along an upper web path on the conveyor system at a distance from the first web to define an electrode handling space.

Referring to step1002, one or more electrodes are positioned on the lower web on the conveyor. In one or more embodiments, only one type of electrode is placed on the conveyor from one or both sides of the conveyor. In other embodiments, the anodes are placed on the conveyor from a first side of the conveyor, and the cathodes are placed on the conveyor from a second side of the conveyor. The material feeds provide sheets of electrode material to their respective electrode cutting modules. The cutting modules receive their respective sheets and cut from the sheets electrodes and place the electrodes onto the conveyor through the electrode handling space.

The external feed rollers receive a sheet of electrode material and pull it into a first cutting area. The internal feed rollers receive a portion of the sheet and help position the sheet for the first stage of cutting by the first tool, which forms slits in the sheet that will define the lateral sides of the electrode, including any tabs. One end of the sheet is positioned in the first area and the other end is positioned in the second cutting area when the lateral sides are being cut. Once the lateral sides of the electrode are formed, the feed rollers cooperatively position the perforated sheet into the second area for cutting the longitudinal sides of the electrode using the second tool, as discussed in more detail below.

In one or more embodiments, depending on the type of electrode material, the first tool is a match metal tool with a first punch assembly and a second punch assembly. However, in one or more embodiments, such as for embodiments forming anodes from thicker material, the second punch assembly includes a steel rule die. The first punch assembly is positioned on a first side of the internal feed rollers, and when the press actuator actuates the ram, the ram causes the punch of the first assembly to shift toward the complementary lower die plate to cooperatively form the lateral sides and tabs in the electrodes. Meanwhile, the second punch assembly, which is spaced apart from the first punch assembly and located on a second side of the internal feed rollers, is pushed by the ram so that its punch is actuated toward its complementary lower die plate to cooperatively form the lateral sides in the electrodes opposite the tabs. The actuation of the ram also causes the second tool to be actuated so that its upper punch shifts toward the steel rule cutting surfaces to form the longitudinal sides of the electrodes in a sheet that had previously been cut by the first tool.

Once the electrodes are cut from the sheet, the magnetic clamp hitch feed shifts the electrodes toward the stationary clamp assembly and the pistons are actuated to retract the magnets below the surfaces of the cutting blocks to release the electrodes. When the magnetic clamp hitch feed moves the perforated electrode material sheet into position, it simultaneously moves the previous cycle's completed electrodes into the load area or onto the staging plate by the magnets proximal to the staging plate. The stationary clamp assembly receives the electrodes from the magnetic clamp assembly, and the staging magnets secure the electrodes until the pick-and-place assembly pulls the electrodes from the staging plate and transports the electrodes to the conveyor.

The pick-and-place assembly engages the electrodes from the stationary clamp assembly and places them on the conveyor. This step may include measuring pallet registration mark positions, via the outboard cameras, and determining, via the controller, the electrode placement position allowing for a higher placement accuracy than the pallet registration sensor alone. This step may further include determining the precise positions of electrodes via the inboard cameras, and determining, via the controller, the required move to place the electrodes correctly on the pallet.

In one or more embodiments in which the electrode material is porous or otherwise unable to be picked up by a vacuum pick head and is magnet, the electrode material is picked up using the pick head magnets. The pick head magnets magnetically attract the electrodes and hold the electrodes when in the extended position. When the pick heads are positioned over the lower web on the conveyor, the inner pistons retract the pick head magnets into the magnet chambers so that the top surfaces of the electrodes abut the bottom ends of the outer pistons. The inner pistons pull the magnets away from the electrodes so that the electrodes are distanced from the magnetic field of the magnets, thereby reducing the attractive forces and releasing the electrodes onto the lower web on the conveyor.

Referring to step1003, the upper web is guided onto the electrodes located on the lower web. This step may include correcting, via the phase adjuster, any different path length between the upper and lower webs. This includes directing, via the conveyor, the upper and lower webs with the electrodes encapsulated inside the webs to positions beneath the heat press.

Referring to step1004, the electrodes are sealed, via the heat press, in the upper and lower webs. This includes actuating the heated surface of the heat press towards the upper web so that it contacts the top surface of the upper web around the perimeter of the electrode and presses the upper web. The heated surface causes the upper web to partially melt and bond with the lower web around the electrode. In one or more embodiments, this step includes forming one or more slits or perforations in the webs around the perimeter of the electrode.

Referring to step1005, the encapsulated electrode is shifted, via guide rollers, off the conveyor. The tension of the webs induced by the rollers along with movement of the webs pulls the electrodes outside the grip of the magnets of the conveyor. The webs may be directed at least in part via the scrap roller.

Referring to step1006, the electrode encapsulated within portions of the webs is removed from the rest of the webs via the knockout station. This step includes actuating a punch toward the webs and punching the encapsulated electrode out of the web. In one or more embodiments, this step includes positioning the receiver, via the actuator, and catching the electrode in the receiver. This step may also include repositioning the receiver, via the actuator, and catching in the receiver an electrode of an opposite type punched from the web.

The method1000may include additional, less, or alternate steps and/or device(s), including those discussed elsewhere herein.

Additional Considerations

Although the present application sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of the description is defined by the words of the claims set forth in any subsequent regular utility patent application. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical. Numerous alternative embodiments may be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims.

In various embodiments, computer hardware, such as a processing element, may be implemented as special purpose or as general purpose. For example, the processing element may comprise dedicated circuitry or logic that is permanently configured, such as an application-specific integrated circuit (ASIC), or indefinitely configured, such as an FPGA, to perform certain operations. The processing element may also comprise programmable logic or circuitry (e.g., as encompassed within a general-purpose processor or other programmable processor) that is temporarily configured by software to perform certain operations. It will be appreciated that the decision to implement the processing element as special purpose, in dedicated and permanently configured circuitry, or as general purpose (e.g., configured by software) may be driven by cost and time considerations.

Accordingly, the term “processing element” or equivalents should be understood to encompass a tangible entity, be that an entity that is physically constructed, permanently configured (e.g., hardwired), or temporarily configured (e.g., programmed) to operate in a certain manner or to perform certain operations described herein. Considering embodiments in which the processing element is temporarily configured (e.g., programmed), each of the processing elements need not be configured or instantiated at any one instance in time. For example, where the processing element comprises a general-purpose processor configured using software, the general-purpose processor may be configured as respective different processing elements at different times. Software may accordingly configure the processing element to constitute a particular hardware configuration at one instance of time and to constitute a different hardware configuration at a different instance of time.

Similarly, the methods or routines described herein may be at least partially processing element-implemented. For example, at least some of the operations of a method may be performed by one or more processing elements or processing element-implemented hardware modules. The performance of certain of the operations may be distributed among the one or more processing elements, not only residing within a single machine, but deployed across a number of machines. In some example embodiments, the processing elements may be located in a single location (e.g., within a home environment, an office environment or as a server farm), while in other embodiments the processing elements may be distributed across a number of locations.