Patent Description:
The present invention relates to an electrode connection apparatus and an electrode connection automation method using the same, and more particularly to an electrode connection apparatus capable of automatically connecting a new standby electrode roll to an end of a moving electrode roll during an electrode manufacturing process performed as a roll-to-roll process and an electrode connection automation method using the same.

A lithium secondary battery, which is capable of being charged and discharged, has been widely used as an energy source for wireless mobile devices or wearable devices, which are worn on bodies, and has also been used as an energy source for electric vehicles and hybrid electric vehicles presented as alternatives to existing gasoline and diesel vehicles, which cause air pollution.

In the lithium secondary battery, a positive electrode and a negative electrode are stacked in the state in which a separator is interposed therebetween, and lithium ions move between the positive electrode and the negative electrode, whereby the lithium secondary battery is repeatedly charged and discharged.

A process of manufacturing an electrode including the positive electrode and the negative electrode includes a step of coating the remaining part of an electrode sheet wound in the form of a roll, excluding parts at which electrode tabs are to be formed, with an electrode agent, a step of drying and rolling the electrode agent, a step of slitting the electrode sheet, and a step of notching the slit electrode sheet into unit electrodes.

An electrode manufacturing process is performed as a roll-to-roll continuous process. In the case in which an electrode roll wound in the form of a roll is completely consumed while electrodes are continuously manufactured using the electrode roll, a worker stops equipment, connects an edge of the electrode roll that is being used and an edge of a new electrode roll to each other using a tape, and reoperates the equipment.

In the case in which an electrode production process is suspended in order to replace the electrode roll and then the electrode production process is resumed, as described above, productivity is reduced.

In connection therewith, Patent Document <NUM> discloses an electrode production system for secondary batteries capable of connecting a first electrode material mounted to a first electrode material supply reel and a second electrode material mounted to a second electrode material supply reel to each other in order to perform a continuous process, but does not concretely disclose a method of automatically attaching a tape to the first electrode material and the second electrode material using a tape suction plate.

Patent Document <NUM> relates an automatic electrode film replacement apparatus configured such that, when an electrode film wound in the form of a roll is almost completely consumed during a process of continuously transferring the electrode film to manufacture a secondary battery, an edge of the electrode film that is being used and an edge of a new electrode film are automatically connected to each other by joining, whereby the secondary battery manufacturing process is continuously performed without interruption.

Patent Document <NUM> is capable of realizing joint connection when the electrode film that is being used and the new electrode film are moved and disposed so as to face each other, but does not disclose an apparatus capable of transferring the new electrode film to the electrode film that is being used and disposing the new electrode film when the electrode film that is being used is not disposed so as to face the new electrode film.

Therefore, there is a high necessity for technology capable of automatically connecting electrode rolls to each other without intervention of a worker even in the case in which the electrode rolls are not disposed so as to face each other when a continuous electrode manufacturing process is performed, whereby uniform electrode connection quality is achieved irrespective of skill of the worker.

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 connection apparatus capable of continuously supplying an electrode roll without interruption during an electrode manufacturing process, whereby it is possible to improve productivity and to prevent occurrence of defects during an electrode roll connection process, and an electrode connection automation method using the same.

In order to accomplish the above object, an electrode connection apparatus according to the present invention includes a transfer unit configured to transfer a start portion of a standby electrode roll while gripping the start portion, a leading unit configured to move upwards while gripping the start portion of the standby electrode roll transferred by the transfer unit, a first connection unit configured to fix the standby electrode roll transferred by the leading unit thereto, a second connection unit configured to fix an end portion of a moving electrode roll thereto, and a taping unit configured to connect the standby electrode roll and the moving electrode roll to each other.

In the electrode connection apparatus according to the present invention, the transfer unit may be configured to have a structure capable of moving toward the standby electrode roll in a first direction and moving in a second direction opposite the first direction while griping opposite side edges of the start portion of the standby electrode roll.

In the electrode connection apparatus according to the present invention, the leading unit may be configured to move downwards, may be configured to grip an edge of the start portion of the standby electrode roll, and may be configured to move upwards.

In the electrode connection apparatus according to the present invention, the first connection unit may be configured to fix the start portion of the standby electrode roll thereto by suctioning.

In the electrode connection apparatus according to the present invention, the first connection unit may include a moving cutter configured to cut the standby electrode roll.

In the electrode connection apparatus according to the present invention, the standby electrode roll may be fixed to a first surface of the first connection unit, the moving cutter may be disposed at a second surface, which is an outer surface opposite the first surface, and the first connection unit may have a slit such that when the moving cutter moves along the slit, the moving cutter cuts the standby electrode roll.

In the electrode connection apparatus according to the present invention, the first connection unit may be configured to have a structure in which the first connection unit moves toward the second connection unit such that an edge of the start portion of the standby electrode roll abuts the end portion of the moving electrode roll fixed to the second connection unit.

In the electrode connection apparatus according to the present invention, the end portion of the moving electrode roll may be fixed to a second surface of the second connection unit, and the taping unit may be disposed outside a first surface, the first surface being an outer surface opposite the second surface.

In the electrode connection apparatus according to the present invention, the second connection unit may have a penetrated portion configured to receive a tape of the taping unit passing therethrough.

In the electrode connection apparatus according to the present invention, the taping unit may include a supply portion configured to supply a tape, a tape gripper configured to transfer the tape supplied by the supply portion to an attachment portion, and the attachment portion being configured to move to an electrode roll connection portion while fixing the tape, and the tape gripper may have a tape cutter configured to cut the tape.

In addition, the present invention provides an electrode connection automation method using the electrode connection apparatus, the electrode connection automation method including (a) transferring the start portion of the standby electrode roll while gripping the start portion, (b) moving the leading unit downwards, gripping the start portion of the standby electrode roll, and transferring the start portion of the standby electrode roll to the first connection unit, (c) cutting the start portion of the standby electrode roll, and (d) connecting the standby electrode roll and a moving electrode roll to each other.

The electrode connection automation method according to the present invention may include moving the standby electrode roll in a direction toward the moving electrode roll after step (c).

In the electrode connection automation method according to the present invention, step (d) may include mounting a tape to the attachment portion of the taping unit and attaching the tape to a connection portion at which the start portion of the standby electrode roll and the end portion of the moving electrode roll are connected to each other.

As is apparent from the above description, an electrode connection apparatus according to the present invention includes a transfer unit and a leading unit. Even though a start portion of a standby electrode roll and an end portion of a moving electrode roll do not face each other in parallel with each other, therefore, it is possible to automatically connect the electrode rolls to each other.

Also, in the case in which the electrode connection apparatus according to the present invention is used, a tape is attached to only one surface of each of the standby electrode roll and the moving electrode roll, whereby it is possible to simplify a connection process, and therefore it is possible to improve productivity.

In addition, all numeric ranges include the lowest value, the highest value, and all intermediate values therebetween unless the context clearly indicates otherwise.

Embodiments of the present invention will be described in detail with reference to the accompanying drawings.

<FIG> is a perspective view of an electrode connection apparatus according to the present invention.

Referring to <FIG>, the electrode connection apparatus according to the present invention includes a transfer unit <NUM> configured to transfer a start portion <NUM> of a standby electrode roll in a state of gripping the start portion, a leading unit <NUM> configured to move upwards in a state of gripping the start portion <NUM> of the standby electrode roll transferred by the transfer unit <NUM>, a first connection unit <NUM> configured to fix the standby electrode roll <NUM> transferred by the leading unit <NUM>, and a second connection unit <NUM> configured to fix an end portion of a moving electrode roll <NUM>.

An electrode connection automation method using the electrode connection apparatus includes (a) a step of transferring a start portion <NUM> of a standby electrode roll in a state of gripping the start portion, (b) a step of the leading unit <NUM> moving downwards to grip the start portion <NUM> of the standby electrode roll and transferring the start portion <NUM> of the standby electrode roll to the first connection unit <NUM>, (c) a step of cutting the start portion <NUM> of the standby electrode roll, and (d) a step of connecting the standby electrode roll <NUM> and a moving electrode roll <NUM> to each other.

In addition, a process of moving the standby electrode roll <NUM> in a direction toward the moving electrode roll <NUM> after step (c) may be included, and step (d) may include a process of mounting a tape to an attachment portion of a taping unit and a process of attaching the tape to a connection portion at which the start portion of the standby electrode roll and an end portion of the moving electrode roll are connected to each other.

The transfer unit <NUM>, the leading unit <NUM>, the first connection unit <NUM>, and the second connection unit <NUM> shown in <FIG> constitute an embodiment. The structures of the units are not limited to structures shown in this specification as long as the units are capable of performing functions that will be described below.

In a concrete example, the transfer unit <NUM> includes two transfer grippers <NUM>. The transfer grippers <NUM> are disposed spaced apart from each other so as to grip opposite side edges of the standby electrode roll in a moving direction thereof. In addition, the transfer grippers <NUM> move toward the standby electrode roll <NUM>, grip the standby electrode roll <NUM>, and transfer the standby electrode roll in a direction toward the leading unit within a predetermined section in a state of being mounted to the transfer unit <NUM>.

The transfer unit <NUM> moves toward the standby electrode roll <NUM> in a first direction, which is an x+ direction, and grips the opposite side edges of the start portion <NUM> of the standby electrode roll using the transfer grippers <NUM>. When the transfer unit moves in a second direction, which is an x- direction, in this state, the standby electrode roll <NUM> is withdrawn.

<FIG> is a perspective view showing a process of transferring the standby electrode roll using the transfer unit and the leading unit of <FIG>.

Referring to <FIG>, when the transfer unit <NUM> moves in the x- direction in the state in which the transfer grippers <NUM> of the transfer unit grip the opposite side edges of the start portion <NUM> of the standby electrode roll <NUM>, the standby electrode roll <NUM> is withdrawn.

When the start portion <NUM> of the standby electrode roll reaches under the leading unit <NUM>, the transfer grippers <NUM> are rotated in a direction indicated by an arrow such that an edge of the start portion <NUM> of the standby electrode roll faces the leading unit <NUM>. Even though the leading unit <NUM> moves only in an upward-downward direction, therefore, a process of the leading unit <NUM> gripping the start portion <NUM> of the standby electrode roll may be easily performed.

In order for the leading unit <NUM> to grip the start portion <NUM> of the standby electrode roll, the length of a length adjustment portion <NUM> of the leading unit <NUM> is increased, whereby a leading gripper <NUM> may grip the start portion <NUM> of the standby electrode roll, the edge of which is bent upwards. When the length of the length adjustment portion <NUM> is decreased in the state in which the leading gripper <NUM> grips the edge of the start portion <NUM> of the standby electrode roll, the start portion <NUM> of the standby electrode roll may be moved upwards.

<FIG> is a perspective view showing a process of cutting the standby electrode roll using the first connection unit of <FIG>.

Referring to <FIG>, the start portion <NUM> of the standby electrode roll moved upwards by the leading unit <NUM> is fixed to a first surface <NUM> of the first connection unit <NUM>.

The first surface <NUM> may be configured as a suction portion. For example, a vacuum hole may be formed in a first surface <NUM>, and a vacuum decompression cylinder may be coupled to the first connection unit <NUM>. Consequently, the standby electrode roll <NUM> may be fixed to the first surface <NUM> by suctioning of the suction portion.

The first connection unit <NUM> may be provided with a moving cutter <NUM> configured to cut the standby electrode roll <NUM>. The cutting position of the standby electrode roll <NUM> may be set in consideration of the position of the electrode roll connection portion at which the standby electrode roll <NUM> and the moving electrode roll <NUM> are connected to each other, and then cutting may be performed by the moving cutter <NUM>.

The standby electrode roll is fixed to the first surface <NUM> of the first connection unit <NUM>, and the moving cutter <NUM> is disposed at a second surface <NUM>, which is an outer surface opposite the first surface <NUM>. The moving cutter <NUM> is disposed such that a part of a knife edge <NUM> protrudes outwards from one side edge portion of the first surface <NUM>. In this state, the moving cutter <NUM> cuts the standby electrode roll <NUM> while moving to the other side edge portion of the first surface <NUM>. A slit <NUM> is formed in the first connection unit <NUM> such that the moving cutter <NUM> can be moved as described above.

A residual electrode <NUM> formed as the result of cutting performed by the moving cutter <NUM> is removed.

<FIG> is a perspective view showing movement of the standby electrode roll cut in <FIG> to the second connection unit of <FIG>.

Referring to <FIG>, an end portion <NUM> of the moving electrode roll <NUM> is fixed to a second surface <NUM> of the second connection unit <NUM>, and a taping unit <NUM> is disposed outside a first surface <NUM>, which is an outer surface opposite the second surface <NUM>.

The second surface <NUM> of the second connection unit <NUM> may be configured as a suction portion. For example, a vacuum hole may be formed in the second surface <NUM>, and a vacuum decompression cylinder may be coupled to the second connection unit <NUM>. Consequently, the moving electrode roll <NUM> may be fixed to the second surface <NUM> by suctioning of the suction portion.

The first connection unit <NUM> moves toward the second connection unit <NUM> such that the edge of the start portion <NUM> of the standby electrode roll abuts the end portion <NUM> of the moving electrode roll <NUM>.

The standby electrode roll <NUM> is attached to the second surface <NUM> of the second connection unit <NUM> such that the start portion <NUM> of the standby electrode roll and the end portion <NUM> of the moving electrode roll <NUM> come into contact with each other. At this time, air suctioning performed by the suction portion of the first connection unit <NUM> to suction the standby electrode roll <NUM> is interrupted, and the second connection unit <NUM> starts to suction the standby electrode roll <NUM>, whereby the standby electrode roll <NUM> is fixed to the second surface <NUM> of the second connection unit <NUM>.

A tape is attached to the electrode roll connection portion at which the standby electrode roll attached to the second surface <NUM> of the second connection unit <NUM> and the moving electrode roll join each other using the taping unit <NUM> disposed outside the first surface <NUM> of the second connection unit <NUM>. The second connection unit <NUM> is provided with a penetrated portion <NUM>, through which the tape of the taping unit <NUM> passes.

<FIG> is a perspective view showing a process of attaching a tape to the electrode roll connection portion.

Referring to <FIG> together with <FIG>, the taping unit <NUM> includes a supply portion <NUM> configured to supply a tape, a tape gripper <NUM> configured to withdraw the tape supplied by the supply portion <NUM> in a state of gripping the tape such that the tape is disposed at the outer surface of an attachment portion <NUM>, and the attachment portion <NUM> configured to move to the electrode roll connection portion in a state of fixing the tape. In addition, the tape gripper <NUM> is provided with a tape cutter (not shown) configured to cut the tape.

The tape gripper <NUM> grips an edge of a tape roll, and disposes the tape such that a non-adhesive surface of the tape is located at the outer surface of the attachment portion <NUM>. At this time, the attachment portion fixes the non-adhesive surface of the tape by suctioning. Suctioning of the attachment portion may be performed in the same manner as the suction portion of each of the first connection unit and the second connection unit. A vacuum decompression suctioning method may be used.

The tape gripper <NUM> returns to the position before the tape is transferred, and the tape withdrawn from the tape roll is cut in a state of being gripped. At this time, the tape is cut to a length necessary to be attached to the electrode roll connection portion, and is attached to the attachment portion <NUM>.

The attachment portion <NUM> is movable by a transfer means, and may pass through the penetrated portion <NUM> formed in the second connection unit <NUM> in order to attach the tape to the electrode roll connection portion.

<FIG> is a plan view showing the state in which the standby electrode roll and the moving electrode roll are connected to each other.

Referring to <FIG>, the state in which the tape <NUM> is attached to the electrode roll connection portion <NUM> at which the moving electrode roll <NUM> and the standby electrode roll <NUM> are connected to each other, whereby the two electrode rolls are connected to each other, is shown.

Since the edge of the standby electrode roll <NUM> is cut by the moving cutter, which moves along the slit formed in the first connection unit, the standby electrode roll may be cut in parallel to a width direction a of the electrode roll.

As a result, the line along which the ends of the standby electrode roll and the moving electrode roll join each other at the electrode roll connection portion <NUM> may be straight. Consequently, overlapping between both electrodes at the electrode roll connection portion <NUM> may be minimized, whereby it is possible to prevent occurrence of a difference in thickness at the electrode roll connection portion <NUM>.

In the case in which the electrode connection apparatus according to the present invention and the electrode connection automation method using the electrode connection apparatus are used, as described above, it is possible to automatically connect the standby electrode roll and the moving electrode roll to each other. Consequently, it is not necessary to suspend the process in order to connect the electrode rolls to each other, and the electrode roll connection portion may be uniformly formed, whereby it is possible to improve productivity in an electrode manufacturing process.

Those skilled in the art to which the present invention pertains will appreciate that various applications and modifications are possible within the scope of the appended claims.

Claim 1:
An electrode connection apparatus comprising:
a transfer unit (<NUM>) configured to transfer a start portion (<NUM>) of a standby electrode roll while gripping the start portion;
a leading unit (<NUM>) configured to move upwards while gripping the start portion (<NUM>) of the standby electrode roll transferred by the transfer unit;
a first connection unit (<NUM>) configured to fix the standby electrode roll (<NUM>) transferred by the leading unit (<NUM>) thereto;
a second connection unit (<NUM>) configured to fix an end portion (<NUM>) of a moving electrode roll thereto; and
a taping unit (<NUM>) configured to connect the standby electrode roll (<NUM>) and the moving electrode roll (<NUM>) to each other.