Abstract:
A materials exchanging device includes a supply material unit to couple to a supply material roll and supplying materials to a winding member; and a standby material unit to couple to a standby material roll and hinged to the supply material unit, wherein an angle of the standby material roll with respect to the supply material unit varies due to hinge-rotation of the standby material unit.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    Korean Patent Application No. 10-2015-0157467, filed on Nov. 10, 2015, in the Korean Intellectual Property Office, and entitled: “Materials Exchanging Device of Winding Equipment for Secondary Battery,” is incorporated by reference herein in its entirety. 
       BACKGROUND 
       [0002]    1. Field 
         [0003]    Exemplary embodiments relate to a materials exchanging device of winding equipment for a secondary battery. 
         [0004]    2. Description of the Related Art 
         [0005]    In general, a manufacturing method of a lithium ion secondary battery may include providing an electrode assembly by stacking a first separator, a negative electrode plate, a second separator, and a positive electrode plate and winding the stacked structure, sealing the electrode assembly, and injecting an electrolyte into a case. 
       SUMMARY 
       [0006]    According to exemplary embodiments, there is provided a materials exchanging device of winding equipment for a secondary battery, the materials exchanging device may a supply material unit to couple to a supply material roll and supplying materials to a winding member; and a standby material unit to couple to a standby material roll and hinged to the supply material unit, wherein an angle of the standby material roll has angle varying with respect to the supply material unit varies due to by hinge-rotation of the standby material unit. 
         [0007]    The supply material unit may include a supply rotation shaft about which the supply material roll is rotated; and a plate unit shaped to allow the supply rotation shaft to pass therethrough. 
         [0008]    When materials wound on the supply material roll are consumed, the supply material unit may shift the supply rotation shaft to an inside of the plate unit to replace the supply material roll with the standby material roll. 
         [0009]    The supply rotation shaft may pass through a throughhole of the plate unit, and the throughhole may have a smaller diameter than the supply material roll. 
         [0010]    The standby material unit may include a second plate unit hinged to the supply material unit; a coupling shaft protruding from one surface of the second plate unit and to couple to the standby material roll; and a transfer plate positioned between the standby material roll and the second plate unit and pushing the standby material roll along the coupling shaft. 
         [0011]    The standby material unit may push the standby material roll along the coupling shaft from a position at which the coupling shaft and a rotation coupling shaft of the supply material unit are extended in a same line. 
         [0012]    The standby material unit may further include a transfer unit including at least one pair of support members coupled to each other about a hinge shaft between the transfer plate and the second plate unit. 
         [0013]    In an extended state of the transfer unit, the transfer plate and the second plate unit may be separated from each other by a maximum distance that is longer than or equal to a length of the coupling shaft. 
         [0014]    The transfer unit may apply a pressure to the transfer plate. 
         [0015]    The materials exchanging device may further include at least one guide roller protruding from the plate unit. 
         [0016]    According to another exemplary embodiment a method of manufacturing a battery may comprise; supplying a first separator from a first separator roll, a second separator from a second separator roll, a negative electrode plate from a negative electrode plate roll, and a positive electrode plate from a positive electrode plate roll; stacking the first separator, the negative electrode plate, the second separator, and the positive electrode plate such that a stacked structure is formed; rotating the stacked structure in one direction with a winding member; exchanging one of the first separator roll, the second separator roll, the negative electrode plate roll, or the positive electrode plate roll with a standby material roll using the materials exchanging device of the exemplary embodiment. 
         [0017]    According to an exemplary embodiment, a method of manufacturing a battery may comprise; supplying a plurality of supply material rolls, each of the supply material rolls including material of at least one of a first separator, a second separator, a negative electrode plate, and a positive electrode plate; stacking the material of the plurality of supply material rolls such that a stacked structure is formed; rotating the stacked structure in one direction with a winding member; exchanging one of the supply material rolls with a standby material roll using a materials exchanging device, wherein the materials exchanging device includes: a supply material unit coupled to at least one of the supply material rolls and supplying the material of the at least one supply material roll to the winding member; and a standby material unit coupled to the standby material roll and hinged to the supply material unit, wherein an angle of the standby material roll with respect to the supply material unit varies based on hinge-rotation of the standby material unit. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    Features will become apparent to those of ordinary skill in the art by describing in detail exemplary embodiments with reference to the attached drawings in which: 
           [0019]      FIG. 1  illustrates a schematic diagram showing a manufacturing method of a secondary battery; 
           [0020]      FIG. 2  illustrates a schematic diagram of a materials exchanging device of winding equipment for a secondary battery according to an embodiment; 
           [0021]      FIG. 3  illustrates a detailed diagram showing a configuration of a standby material unit for pushing standby materials in the materials exchanging device of winding equipment for a secondary battery according to an embodiment; 
           [0022]      FIG. 4  illustrates a diagram showing a state in which a supply material roll is separated from a supply material unit when a standby material unit is folded in the materials exchanging device of winding equipment for a secondary battery according to an embodiment; 
           [0023]      FIG. 5  illustrates a diagram showing a state in which a supply rotation shaft of a supply material unit has moved forward in the materials exchanging device of winding equipment for a secondary battery according to an embodiment; and 
           [0024]      FIG. 6  illustrates a diagram showing a state in which a standby material roll is coupled to a supply rotation shaft by an operation of a pushing unit in the materials exchanging device of winding equipment for a secondary battery according to an embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0025]    Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings; however, they may be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey exemplary implementations to those skilled in the art. 
         [0026]    In the drawing figures, the dimensions of layers and regions may be exaggerated for clarity of illustration. Like reference numerals refer to like elements throughout. 
         [0027]      FIG. 1  is a schematic diagram showing a manufacturing method of a secondary battery. 
         [0028]    As shown in  FIG. 1 , in order to manufacture a secondary battery, a first separator  11 , a second separator  12 , a negative electrode plate  13  and a positive electrode plate  14  may be supplied. In more detail, the first separator  11  is supplied from a first separator roll  11   a  wound multiple times, the second separator  12  is supplied from a second separator roll  12   a  wound multiple times, the negative electrode plate  13  is supplied from a negative electrode plate roll  13   a  wound multiple times, and the positive electrode plate  14  is supplied from a positive electrode plate roll  14   a  wound multiple times. 
         [0029]    In addition, the negative electrode plate  13  may be positioned between the first and second separators  11  and  12  and the positive electrode plate  14  may be positioned behind the second separator  12 . For example, a stacked structure, including the first separator  11 , the negative electrode plate  13 , the second separator  12 , and the positive electrode plate  14 , may be provided. Additionally, the stacked structure may be rotated in one direction by a winding member  15 , thereby obtaining or producing the electrode assembly having a jelly-roll configuration. 
         [0030]    In the materials exchanging device according to the exemplary embodiment, rolls may be exchanged when the first and second separators  11  and  12 , the negative electrode plate  13  and/or the positive electrode plate  14  are supplied, while reducing a volume or size of the materials exchanging device. The materials exchanging device will now be described in detail. 
         [0031]      FIG. 2  is a schematic diagram of a materials exchanging device of winding equipment for a secondary battery according to an exemplary embodiment and  FIG. 3  is a detailed diagram showing a configuration of a standby material unit for pushing standby materials in the materials exchanging device of winding equipment for a secondary battery according to an exemplary embodiment. 
         [0032]    As shown in  FIG. 2 , the materials exchanging device  100  of winding equipment for a secondary battery according to an exemplary embodiment may include a supply material unit  110 , a frame spacer unit  120 , and a standby material unit  130 . 
         [0033]    The supply material unit  110  may include a supply rotation shaft  111  coupled to the supply material roll  1 , a plate unit  112  shaped such that the supply rotation shaft  111  passes therethrough, and a guide roller unit  113  protruding from the plate unit  112 . 
         [0034]    The supply rotation shaft  111  may be coupled to a separate motor provided therein to receive a rotational force and may be rotated in a direction. The supply rotation shaft  111  may unroll a supply material from the supply material roll  1  coupled by the rotation of the supply rotation shaft  111 . The supply rotation shaft  111  may horizontally shift its end  111   a  to which the supply material roll  1  is applied. In more detail, the supply rotation shaft  111  may be provided such that the end  111   a  is shifted back and forth on the same line with the supply rotation shaft  111 . Therefore, if the end  111   a  moves forward to then be protruded and exposed to an outside of the plate unit  112 , the supply material roll  1  may be coupled to the end  111   a . In addition, if the end  111   a  moves backward to then be positioned within the plate unit  112 , the end  111   a  may not be exposed and the supply material roll  1  coupled thereto may fall and be separated from the end  111   a , which will later be described. 
         [0035]    The plate unit  112  may be provided substantially perpendicular to the supply rotation shaft  111 . The plate unit  112  may include a throughhole  112   a  through which the supply rotation shaft  111  passes. The plate unit  112  may be used for separating the supply material roll  1  from the supply rotation shaft  111  after materials of the supply material roll  1  are consumed. The throughhole  112   a  of the plate unit  112  may have a larger diameter than the supply rotation shaft  111  and a smaller diameter than the supply material roll  1 , even after the materials have been consumed. When the end  111   a  of the supply rotation shaft  111  moves backward (e.g., in a negative y-axis direction of  FIG. 2 ) to separate the supply material roll  1  from the end  111   a  of the supply rotation shaft  111 , the end  111   a  may pass through the throughhole  112   a  of the plate unit  112  and move backward to an inside of the plate unit  112 . However, since the supply material roll  1  having the materials consumed cannot pass through the throughhole  112   a , the supply material roll  1  may be prevented from moving backward by the plate unit  112 . Therefore, the supply material roll  1  having the materials consumed may be separated from the end  111   a  of the supply rotation shaft  111 . A separate cylinder may be optionally provided, regardless of the diameter of the throughhole  112   a  of the plate unit  112 , thereby preventing the supply material roll  1  from moving backward by being caught by the separate cylinder. 
         [0036]    The guide roller unit  113  may include at least one guide roller (e.g.,  113   a ,  113   b , and  113   c ) and may protrude from the plate unit  112 . For example, the guide roller unit  113  may include three guide rollers  113   a ,  113   b , and  113   c  and may be substantially parallel with the supply rotation shaft  111 . The guide roller unit  113  may allow the materials unwound from the supply material roll  1  to be unrolled while maintaining an appropriate tension along a predetermined path until the materials reach the winding member  15  shown in  FIG. 1 . To this end, the guide roller unit  113  is configured to be capable of freely axially rotating. 
         [0037]    The frame spacer unit  120  may be coupled to and substantially perpendicular to the plate unit  112  of the supply material unit  110 . The frame spacer unit  120  may have a length such that it protrudes from the plate unit  112  past the end  111   a  of the supply rotation shaft  111 . Therefore, even if the supply material roll  1  is coupled to the end  111   a  of the supply rotation shaft  111 , as will be described later, the standby material unit  130  may be rotated about 90 degrees to be disposed substantially parallel with the supply rotation shaft  111 . 
         [0038]    To this end, the frame spacer unit  120  may include a hinge coupling unit  121  protruding at an end coupled to the standby material unit  130 . The standby material unit  130  may be engaged with the hinge coupling unit  121  and hinged thereto. Accordingly, the standby material unit  130  may be rotated more than 90 degrees about the hinge coupling unit  121 . 
         [0039]    Referring to  FIGS. 2 and 3 , the standby material unit  130  may be coupled to the hinge coupling unit  121  of the frame spacer unit  120 . The standby material unit  130  may include a coupling shaft  131  coupled to a standby material roll  2  which is to replace the supply material roll  1  having the materials consumed, a plate unit  132  supporting the coupling shaft  131 , a transfer plate  133  positioned between the plate unit  132  and the standby material roll  2  and making a surface contact with the standby material roll  2 , and a transfer unit  134  for pushing the transfer plate  133  away from the plate unit  132  along the coupling shaft  131 . 
         [0040]    The coupling shaft  131  may be coupled to the standby material roll  2  in a state in which the standby material unit  130  and the frame spacer unit  120  are extended and substantially aligned. An end  131   a  of the coupling shaft  131  may be exposed to an outside of the standby material roll  2 , thereby maintaining the standby material roll  2  at a stably coupled state. 
         [0041]    The plate unit  132  may support the coupling shaft  131  and structures coupled to a rear surface of the coupling shaft  131 . The plate unit  132  may include a hinge coupling unit  132   a  and a hinge shaft  132   b  to be coupled to the hinge coupling unit  121  of the frame spacer unit  120 . The hinge coupling unit  132   a  of the plate unit  132  may be engaged with the hinge coupling unit  121  of the frame spacer unit  120  to be coupled thereto, and the hinge shaft  132   b  may pass through the hinge coupling unit  132   a  of the plate unit  132  from above the hinge coupling unit  132   a  of the plate unit  132 , so that the plate unit  132  may be maintained in a state in which the plate unit  132  is hinged to the frame spacer unit  120 . As such, the plate unit  132  may be rotated about the hinge shaft  132   b  by about 90 degrees from the position shown in  FIG. 2 . In addition, the plate unit  132  may include a handle  132   c  at its edge, thereby facilitating holding of the plate unit  132  by an operator to rotate the plate unit  132  about the hinge shaft  132   b.    
         [0042]    The transfer plate  133  may be coupled to the coupling shaft  131  and may maintain a state in which the transfer plate  133  makes surface contact with the standby material roll  2 . The transfer plate  133  may move back and forth from the plate unit  132  along the coupling shaft  131 . When the transfer plate  133  moves forward (e.g., in the negative y-axis direction of  FIG. 4 ), the standby material roll  2  may be pushed from the end  131   a  of the coupling shaft  131  to be coupled to the supply rotation shaft  111  of the supply material unit  110 . In addition, the transfer plate  133  may further include a loosened material (LM) guide unit  133   a  that fixes a position of the transfer plate  133 . An end of the standby material roll  2  may be loosened to be fixed during a standby mode, and the LM guide unit  133   a  may be locked on a separate shaft (not shown). If the transfer plate  133  moves backward (e.g., in a positive y-axis direction of  FIG. 4 ) directly after the standby material roll  2  is transferred to the supply rotation shaft  111 , the material may be damaged by the separate shaft. The LM guide unit  133   a  may guide the transfer plate  133  backward to prevent the separate shaft from making contact with the material of the standby material roll  2  when the transfer plate  133  moves backward. 
         [0043]    The transfer unit  134  may be positioned between the transfer plate  133  and the plate unit  132 . The transfer unit  134  may be connected to the transfer plate  133  by an x-type link. In more detail, the transfer unit  134  may have at least a pair of support members  134   a  and  134   b  crossing each other in an X-letter shape, the pair of support members  134   a  and  134   b  may be hinged with respect to a hinge shaft  134   c . Therefore, the support members  134   a  and  134   b  may extend or contract with respect to the hinge shaft  134   c.    
         [0044]    The transfer unit  134  may be contracted and folded during normal operation of the supply material unit  110 . The transfer unit  134  may extend to push the transfer plate  133  away from the plate unit  132  when the standby material roll  2  is to be coupled to the supply rotation shaft  111  of the supply material unit  110 . A maximally extended distance between the transfer plate  133  and the plate unit  132  in a state in which the transfer unit  134  is extended may be longer than or equal to a length of the coupling shaft  131 . Accordingly, the transfer unit  134  may push the standby material roll  2  coupled to the coupling shaft  131  away from the coupling shaft  131  via the transfer plate  133 . Therefore, the standby material roll  2  may be shifted along the coupling shaft  131  to then be coupled to the supply rotation shaft  111  of the supply material unit  110 . Thereafter, the transfer unit  134  may be again contracted and folded to prepare to accommodate another standby material roll. 
         [0045]    Hereinafter, the operation of the materials exchanging device of winding equipment for a secondary battery according to an exemplary embodiment will be described in more detail. 
         [0046]      FIG. 4  is a diagram showing a state in which a supply material roll is separated from a supply material unit when a standby material unit is folded in the materials exchanging device of winding equipment for a secondary battery according to an embodiment,  FIG. 5  is a diagram showing a state in which a supply rotation shaft of a supply material unit has moved forward in the materials exchanging device of winding equipment for a secondary battery according to an embodiment, and  FIG. 6  is a diagram showing a state in which a standby material roll is coupled to a supply rotation shaft by an operation of a pushing unit in the materials exchanging device of winding equipment for a secondary battery according to an embodiment. 
         [0047]    Referring again to  FIG. 2 , in the materials exchanging device  100  of winding equipment for a secondary battery according to an exemplary embodiment, in a state in which the plate unit  132  of the standby material unit  130  is disposed to be substantially aligned with the frame spacer unit  120 , the standby material roll  2  may be coupled to the coupling shaft  131 . In this case, the standby material roll  2  may be maintained at an angle of about 90 degrees with respect to the supply material roll  1 . In such a case, the materials exchanging device  100  occupies a smaller space than in a case where the supply material roll  1  and the standby material roll  2  are disposed to be parallel with each other. Therefore, the size of the materials exchanging device  100  may be reduced. 
         [0048]    As shown in  FIG. 4 , the plate unit  132  of the standby material unit  130  may be rotated about the hinge shaft  132   b  such that the standby material unit  130  is disposed at an angle of about 90 degrees with respect to the frame spacer unit  120 . Therefore, the coupling shaft  131  of the standby material unit  130  may be positioned to be extended on a same line as the supply rotation shaft  111  of the supply material unit  110 . 
         [0049]    Thereafter, the supply rotation shaft  111  of the supply material unit  110  moves backward (e.g., in the negative y-axis direction of  FIG. 4 ), so that the end  111   a  of the supply material unit  110  may be positioned in the inside of the plate unit  112 . In addition, since the throughhole  112   a  of the plate unit  112  may have a smaller diameter than the supply material roll  1  having the materials consumed, the supply material roll  1  may be prevented from moving to the inside of the plate unit  112 . As described above, the supply material roll  1  may be prevented from moving to the inside of the plate unit  112  through a separate cylinder. Therefore, as shown in  FIG. 4 , the supply material roll  1  having the materials consumed may be separated from the supply rotation shaft  111  to then fall downward. Here, the supply material roll  1  may be recovered by an operator for disposal. 
         [0050]    Referring to  FIG. 5 , the supply rotation shaft  111  of the supply material unit  110  moves to be exposed such that the end  111   a  may again be protruded to the outside of the plate unit  112 . Therefore, the supply material roll  1  may be removed, as indicated above, and the supply rotation shaft  111  without the supply material roll  1  thereon may be protruded to the outside of the plate unit  112 . 
         [0051]    Referring to  FIG. 6 , the transfer unit  134  of the standby material unit  130  may be extended to push the transfer plate  133  toward the supply material unit  110 . Accordingly, the transfer plate  133  may push the standby material roll  2  along the coupling shaft  131 , and the standby material roll  2  may be coupled to the supply rotation shaft  111  of the supply material unit  110 . Thereafter, coupling of an end of the supply material roll  1  having the materials consumed to an end of the standby material roll  2  may be performed. 
         [0052]    Accordingly, in the materials exchanging device  100  of winding equipment for a secondary battery according to an exemplary embodiment, the standby material unit  130  may be maintained orthogonal to the supply material unit  110 . During exchange of the supply material roll  1  and the standby material roll  2 , the standby material unit  130  may be moved to about 90 degrees with respect to the supply material roll  1  by rotating the standby material unit  130  by about 90 degrees. This configuration may reduce the size of the materials exchanging device  100 . 
         [0053]    In addition, in the materials exchanging device  100  of winding equipment for a secondary battery according to an exemplary embodiment, when materials of the supply material roll  1  are consumed, the supply rotation shaft  111  of the supply material unit  110  moves backward to remove the supply material roll  1  and the standby material roll  2  may be coupled to the supply rotation shaft through  111  through the transfer unit  134  of the standby material unit  130 , thereby facilitating replacement of materials. 
         [0054]    By way of summation and review, a positive electrode plate, a negative electrode plate, and separators may be provided in roll-shaped configurations, respectively, to then be supplied. If base materials wound on a roll are consumed, exchange of the roll with another roll may be needed. 
         [0055]    In view of characteristics of base materials for the separator, there may be a dimensional restriction for the diameter of the separator, and rolls may need to be replaced frequently. 
         [0056]    Accordingly, in providing an electrode assembly, an operating suspension time of winding equipment may be lengthened due to frequent replacement of rolls, thereby lowering manufacturability of a lithium ion secondary battery. 
         [0057]    Exemplary embodiments may provide a materials exchanging device of winding equipment for a secondary battery, which may rapidly and accurately replace base materials for the secondary battery while having a simplified configuration and while occupying a reduced volume or space for installation. 
         [0058]    As described above, in the materials exchanging device of winding equipment for a secondary battery according to exemplary embodiments, the standby material unit may be maintained to be orthogonal to the supply material unit and at about 90 degrees with respect to the supply material roll. This configuration permits reduction of the size or volume of the materials exchanging device by allowing rotation of the standby material unit by about 90 degrees when the supply material roll is exchanged with the standby material roll. 
         [0059]    In addition, in the materials exchanging device of winding equipment for a secondary battery according to exemplary embodiments, when materials of the supply material roll are consumed, the supply rotation shaft of the supply material unit moves backward to remove the supply material roll and the standby material roll is coupled to the supply rotation shaft through the transfer unit of the standby material unit, thereby facilitating replacement of materials. 
         [0060]    Example embodiments have been disclosed herein, and although specific terms are employed, they are used and are to be interpreted in a generic and descriptive sense only and not for purpose of limitation. In some instances, as would be apparent to one of ordinary skill in the art as of the filing of the present application, features, characteristics, and/or elements described in connection with a particular embodiment may be used singly or in combination with features, characteristics, and/or elements described in connection with other embodiments unless otherwise specifically indicated. Accordingly, it will be understood by those of skill in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention as set forth in the following claims.