Sheet Cutting and Fusion Apparatus

Abstract

A sheet cutting and fusion apparatus including upper and lower cutters at uppermost and lowermost surfaces, respectively, of a plurality of overlapping sheets. The upper and lower cutters includes first and second cutting surfaces configured for contacting the lower cutter without any step when the upper cutter is moved vertically and the upper cutter without any step when the lower cutter is moved vertically, respectively; first and second fusion portions parallel to the first cutting surface and to the second cutting surface, respectively; first and second steps extending between the first cutting surface and first fusion portion and extending between the second cutting surface and second fusion portion, respectively; lower and upper surfaces configured to face one of the sheets, respectively; and first and second connection portions each having a curved corner connecting the lower surface and first fusion portion and connecting the upper surface and second fusion portion, respectively.

Claims

1. A sheet cutting and fusion apparatus comprising: an upper cutter disposed at an uppermost surface of a plurality of overlapping sheets; and a lower cutter disposed at a lowermost surface of the plurality of overlapping sheets, wherein the upper cutter comprises: a first cutting surface configured to come into contact with and move past a portion of the lower cutter without moving horizontally when the upper cutter is moved vertically; a first fusion portion parallel to the first cutting surface; and a first step extending between the first cutting surface and the first fusion portion, and wherein the lower cutter comprises: a second cutting surface configured to come into contact with and move past a portion of the upper cutter without moving horizontally when the lower cutter is moved vertically; a second fusion portion constituted by a surface parallel to the second cutting surface; and a second step extending between the second cutting surface and the second fusion portion.

2. The sheet cutting and fusion apparatus according to claim 1, wherein at least a portion of the upper cutter and at least a portion of the lower cutter are configured for being heated.

3. The sheet cutting and fusion apparatus according to claim 1, wherein either one or both of the upper cutter and the lower cutter is moved such that the first cutting surface and the second cutting surface come into contact with each other without any step, and either one or both of the sheets are cut due to compression, shearing force, or melting by an intersection between the first cutting surface and the second cutting surface.

4. The sheet cutting and fusion apparatus according to claim 1, wherein either one or both of the upper cutter and the lower cutter is moved such that the first cutting surface and the second cutting surface overlap each other, and the plurality of overlapping sheets are cut due to compression, shearing force, or melting by the first fusion portion and the second fusion portion.

5. The sheet cutting and fusion apparatus according to claim 1, wherein either one or both of the upper cutter and the lower cutter is moved such that the first cutting surface and the second cutting surface overlap each other, and the plurality of overlapping sheets are cut due to compression, shearing force, or melting by the first step and the second step.

6. The sheet cutting and fusion apparatus according to claim 1, wherein, when the sheets are disposed at any one of between the first cutting surface and the second cutting surface, between the first fusion portion and the second fusion portion, and between the first step and the second step, the sheets are fused.

7. The sheet cutting and fusion apparatus according to claim 5, wherein the first cutting surface, the first fusion portion, the second cutting surface, and the second fusion portion have an identical temperature, and the temperature thereof is lower than a temperature of the first step and the second step.

8. The sheet cutting and fusion apparatus according to claim 1, wherein the upper cutter is disposed at the uppermost surface of the sheets, the lower cutter is disposed at the lowermost surface of the sheets, and the lower surface of the upper cutter and the upper surface of the lower cutter are disposed parallel to the sheets.

9. The sheet cutting and fusion apparatus according to claim 1, wherein the upper cutter is disposed at the uppermost surface of the sheets, the lower cutter is disposed at the lowermost surface of the sheets, and the lower surface of the upper cutter and the upper surface of the lower cutter are disposed inclined relative to the sheets.

10. The sheet cutting and fusion apparatus according to claim 1, wherein the sheets comprise a first sheet and a second sheet, further comprising: stacked electrodes stacked between the first sheet and the second sheet, wherein each of the stacked electrodes is spaced apart from at least one another one of the stacked electrodes by a predetermined distance, and the predetermined distance is greater than a sum of a length from the first connection portion to the first cutting surface and a length from the second connection portion to the second cutting surface.

11. The sheet cutting and fusion apparatus according to claim 1, wherein a height of each of the first step and the second step is equal to or less than a thickness of a combination of at least two sheets that overlap each other.

12. A unit cell manufactured by cutting sheets using the sheet cutting and fusion apparatus according to claim 1, wherein the unit cell is a mono-cell configured such that a first sheet, a first electrode, a second sheet, and a second electrode are stacked or a bi-cell configured such that a first electrode, a first sheet, a second electrode, a second sheet, and a first electrode are stacked, and sheets of one-direction outer peripheries of each of the mono-cell and the bi-cell parallel to each other are thermally fused.

13. The sheet cutting and fusion apparatus according to claim 1, further comprising: a lower surface configured to face one of the plurality of overlapping sheets; and an upper surface configured to face one of the plurality of overlapping sheets.

14. The sheet cutting and fusion apparatus according to claim 1, further comprising: a first connection portion having a curved corner that connects the lower surface and the first fusion portion to each other; and a second connection portion having a curved corner that connects the upper surface and the second fusion portion to each other.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] FIG. 1 is a schematic perspective view of a conventional sheet cutting apparatus.

[0049] FIG. 2 is a cross-sectional view showing a sequence of sheet cutting performed by the conventional sheet cutting apparatus.

[0050] FIG. 3 is a schematic elevation view showing the construction of an upper cutter and a lower cutter when the conventional sheet cutting apparatus is applied to two sheets.

[0051] FIG. 4 is an elevation view showing a sheet cutting and fusion apparatus according to a first embodiment.

[0052] FIG. 5 is an elevation view showing a sheet cutting and fusion apparatus according to a second embodiment.

[0053] FIG. 6 is a set of elevation views showing a process of cutting and fusing sheets using the sheet cutting and fusion apparatus according to the second embodiment.

[0054] FIG. 7 is a set of elevation views showing a process of cutting and fusing sheets using a sheet cutting and fusion apparatus according to a third embodiment.

[0055] FIG. 8 is a view showing a unit cell manufactured using the sheet cutting and fusion apparatus according to a further embodiment.

DETAILED DESCRIPTION

[0056] Now, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings such that the preferred embodiments of the present invention can be easily implemented by a person having ordinary skill in the art to which the present invention pertains. In describing the principle of operation of the preferred embodiments of the present invention in detail, however, a detailed description of known functions and configurations incorporated herein will be omitted when the same may obscure the subject matter of the present invention.

[0057] In addition, the same reference numbers will be used throughout the drawings to refer to parts that perform similar functions or operations. In the case in which one part is said to be connected to another part throughout the specification, not only may the one part be directly connected to the other part, but also, the one part may be indirectly connected to the other part via a further part. In addition, that a certain element is included does not mean that other elements are excluded, but rather means that such elements may be further included unless mentioned otherwise.

[0058] In addition, a description to embody elements through limitation or addition may be applied to all inventions, unless particularly restricted, and does not limit a specific invention.

[0059] Also, in the description of the invention and the claims of the present application, singular forms are intended to include plural forms unless mentioned otherwise.

[0060] Also, in the description of the invention and the claims of the present application, “or” includes “and” unless mentioned otherwise. Therefore, “including A or B” means three cases, namely, the case including A, the case including B, and the case including A and B.

[0061] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0062] FIGS. 4 to 8 illustrate embodiments of a sheet cutting and fusion apparatus according to the present invention. In FIGS. 4 to 8, a sheet used for a battery, i.e. a separator, is described by way of example. However, the sheet cutting and fusion apparatus according to the present invention is applicable to any sheet as long as the sheet is thin and is configured such that a part of one sheet and a part of another sheet can be melted and coupled to each other.

[0063] Referring to FIG. 4, first electrodes 10 are disposed spaced apart from each other by a predetermined distance W on an upper surface of an upper sheet 30, which is one of sheets that overlap each other, and second electrodes 20 are disposed spaced apart from each other by the predetermined distance W on an upper surface of a lower sheet 30, which is the other of the sheets that overlap each other.

[0064] The first electrodes 10 and the second electrodes 20 pass through the sheet cutting and fusion apparatus, which is constituted by an upper cutter 100 and a lower cutter 200, in a state of being disposed so as to completely overlap each other in a y-axis direction, which is a stacking direction, whereby the two sheets 30 that overlap each other may be cut while outer peripheries of the sheets 30 are adhered to each other by thermal fusion.

[0065] Specifically, a sheet cutting and fusion apparatus according to a first embodiment includes an upper cutter 100 disposed at the uppermost surface of at least two sheets 30 that overlap each other and a lower cutter 200 disposed at the lowermost surface of the sheets 30, wherein the upper cutter 100 includes a first cutting surface 130 configured to come into contact with the lower cutter 200 without any step when the upper cutter is moved vertically, a first fusion portion 120 constituted by a surface parallel to the first cutting surface 130 in the state in which a first step 110 is formed so as to extend from the first cutting surface 130, a lower surface 140 configured to face the sheets 30, and a first connection portion 150, which is a curved corner that connects the lower surface 140 and the first fusion portion 120 to each other.

[0066] The lower cutter 200 includes a second cutting surface 230 configured to come into contact with the upper cutter 100 without any step when the lower cutter is moved vertically, a second fusion portion 220 constituted by a surface parallel to the second cutting surface 230 in the state in which a second step 210 is formed so as to extend from the second cutting surface 230, an upper surface 240 configured to face the sheets 30, and a second connection portion 250, which is a curved corner that connects the upper surface 240 and the second fusion portion 220 to each other.

[0067] The sheet cutting and fusion apparatus according to the present invention simultaneously performs a process of cutting the sheets and a process of thermally fusing the outer peripheries of the sheets. Specifically, each of the first connection portion 150, which connects the first fusion portion 120 of the first cutting surface 130 and the lower surface 140 to each other, and the second connection portion 250, which connects the second fusion portion 220 of the second cutting surface 230 and the upper surface 240 to each other, is formed in a curved shape.

[0068] In addition, the step is formed between the first cutting surface 130 and the first fusion portion 120, the step is formed between the second cutting surface 230 and the second fusion portion 220, and the first cutting surface 130 and the second cutting surface 230 are moved so as not to overlap each other.

[0069] Even though the lowermost end of the upper cutter and the uppermost end of the lower cutter intersect so as to be adjacent to each other, therefore, the sheets are not cut, since an empty space is formed therebetween.

[0070] In addition, each of the upper cutter and the lower cutter includes a structure capable of being heated.

[0071] That is, each of the upper cutter and the lower cutter may be configured such that the temperature thereof can be increased to a temperature at which the sheets are melted.

[0072] When the sheets are cut using the upper cutter and the lower cutter, the temperature of each of which has been increased to the sheet melting temperature, sheet adhesion portions at which the melted sheets are attached to each other are formed at opposite sides of a cutting line.

[0073] The upper cutter 100 and/or the lower cutter 200 may be moved such that the first cutting surface 130 and the second cutting surface 230 come into contact with each other without any step, and the sheets 30 may be cut due to compression, shearing force, or melting by intersection between the first cutting surface 130 and the second cutting surface 230.

[0074] The sheet cutting and fusion apparatus shown in FIG. 4 is configured such that, in the state in which the upper cutter 100 is disposed at the upper surface of one of the sheets 30 and the lower cutter 200 is disposed at the lower surface of the other of the sheets 30, the lower surface 140 of the upper cutter 100 and the upper surface 240 of the lower cutter 200 are disposed parallel to the sheets 30.

[0075] Consequently, the electrodes and the sheets 30 moving between the upper cutter 100 and the lower cutter 200 may be supported thereunder.

[0076] FIG. 5 is a view showing a sheet cutting and fusion apparatus according to a second embodiment of the present invention.

[0077] Referring to FIG. 5, first electrodes 10 are disposed spaced apart from each other by a predetermined distance W on an upper surface of an upper sheet 30, which is one of sheets that overlap each other, and second electrodes 20 are disposed spaced apart from each other by the predetermined distance W on an upper surface of a lower sheet 30, which is the other of the sheets that overlap each other.

[0078] The first electrodes 10 and the second electrodes 20 pass through the sheet cutting and fusion apparatus, which is constituted by an upper cutter 300 and a lower cutter 400, in a state of being disposed so as to completely overlap each other in a y-axis direction, which is a stacking direction, whereby the two sheets 30 that overlap each other may be cut while outer peripheries of the sheets 30 are adhered to each other by thermal fusion.

[0079] Specifically, the sheet cutting and fusion apparatus according to the second embodiment includes an upper cutter 300 disposed at the uppermost surface of at least two sheets 30 that overlap each other and a lower cutter 400 disposed at the lowermost surface of the sheets 30, wherein the upper cutter 300 includes a first cutting surface 330 configured to come into contact with the lower cutter 400 without any step when the upper cutter is moved vertically, a first fusion portion 320 constituted by a surface parallel to the first cutting surface 330 in the state in which a first step 310 is formed so as to extend from the first cutting surface 330, a lower surface 340 configured to face the sheets 30, and a first connection portion 350, which is a curved corner that connects the lower surface 340 and the first fusion portion 320 to each other.

[0080] The lower cutter 400 includes a second cutting surface 430 configured to come into contact with the upper cutter 300 without any step when the lower cutter is moved vertically, a second fusion portion 420 constituted by a surface parallel to the second cutting surface 430 in the state in which a second step 410 is formed so as to extend from the second cutting surface 430, an upper surface 440 configured to face the sheets 30, and a second connection portion 450, which is a curved corner that connects the upper surface 440 and the second fusion portion 420 to each other.

[0081] The sheet cutting and fusion apparatus according to the present invention simultaneously performs a process of cutting the sheets and a process of thermally fusing the outer peripheries of the sheets. Specifically, each of the first connection portion 350, which connects the first fusion portion 320 of the first cutting surface 330 and the lower surface 340 to each other, and the second connection portion 450, which connects the second fusion portion 420 of the second cutting surface 430 and the upper surface 440 to each other, is formed in a curved shape.

[0082] In addition, the step is formed between the first cutting surface 330 and the first fusion portion 320, the step is formed between the second cutting surface 430 and the second fusion portion 420, and the first cutting surface 330 and the second cutting surface 430 are moved so as not to overlap each other.

[0083] Even though the lowermost end of the upper cutter and the uppermost end of the lower cutter intersect so as to be adjacent to each other, therefore, the sheets are not cut, since an empty space is formed therebetween.

[0084] In addition, each of the upper cutter and the lower cutter includes a structure capable of being heated.

[0085] That is, each of the upper cutter and the lower cutter may be configured such that the temperature thereof can be increased to a temperature at which the sheets are melted.

[0086] When the sheets are cut using the upper cutter and the lower cutter, the temperature of each of which has been increased to the sheet melting temperature, sheet adhesion portions at which the melted sheets are attached to each other are formed at opposite sides of a cutting line.

[0087] The sheet cutting and fusion apparatus shown in FIG. 5 is configured such that, in the state in which the upper cutter 300 is disposed at the upper surface of one of the sheets 30 and the lower cutter 400 is disposed at the lower surface of the other of the sheets 30, the lower surface 340 of the upper cutter 300 and the upper surface 440 of the lower cutter 400 are disposed inclined relative to the sheets 30.

[0088] FIG. 6 is a view showing a process of cutting and fusing sheets using the sheet cutting and fusion apparatus according to the second embodiment of the present invention.

[0089] Referring to FIG. 6, when sheets 30 are interposed between the first cutting surface 330 and the second fusion portion 420 and between the second cutting surface 430 and the first fusion portion 320 in an overlapping state, the sheets are melted by the upper cutter 300 and the lower cutter 400, which are heated, whereby a thermally fused portion 370 is formed.

[0090] The upper cutter 300 is moved downwards such that the first cutting surface 330 and the second cutting surface 430 face each other in tight contact with each other, and the sheets are melted and adhered to each other before intersection between the first cutting surface 330 and the second cutting surface 430. When the first cutting surface 330 and the second cutting surface 430 intersect each other, particularly when the first corner 360 and the second corner 460 abut each other, the sheets 30 are cut.

[0091] Consequently, the two sheets are cut in the state in which the outer peripheries of the sheets are coupled to each other by thermal fusion while the sheets overlap each other.

[0092] In consideration of the fact that the two sheets are attached to each other in a state of being in tight contact with each other between the first cutting surface of the upper cutter and the second fusion portion of the lower cutter and between the first fusion portion of the upper cutter and the second cutting surface of the lower cutter, the height H of each of the first step 310 and the second step 410 may be equal to or less than the thickness of at least two sheets that overlap each other.

[0093] Referring to FIGS. 5 and 6 together, the sheets include a first sheet and a second sheet stacked in the state in which electrodes are interposed therebetween, the electrodes are disposed spaced apart from each other by a predetermined distance W, and the distance W is greater than the sum of the length from the first connection portion 350 to the first cutting surface 330 and the length from the second connection portion 450 to the second cutting surface 430. In the case in which the distance W between the electrodes is set, as described above, the electrodes are not pressed when the upper cutter and the lower cutter intersect each other, whereby it is possible to prevent damage to the electrodes. In addition, the electrodes may not be disposed at the first connection portion and the second connection portion, whereby it is possible to prevent the electrodes from being separated from the sheets.

[0094] FIG. 7 is a view showing a process of cutting and fusing sheets using a sheet cutting and fusion apparatus according to a third embodiment of the present invention.

[0095] Referring to FIG. 7, an upper cutter 500 is moved downwards such that a first cutting surface 530 of the upper cutter 500 and a second cutting surface 630 of a lower cutter 600 overlap each other, the first cutting surface 530 of the upper cutter 500 and the second cutting surface 630 of the lower cutter 600 do not intersect each other, and the upper cutter is moved downwards until a first step 510 comes into tight contact with a second step 610 in the state in which sheets are located therebetween.

[0096] The two sheets 30 are attached to each other in tight contact with each other between the first cutting surface 530 of the upper cutter and a second fusion portion 620 of the lower cutter and between a first fusion portion 520 of the upper cutter and the second cutting surface 630 of the lower cutter, whereby a thermally fused portion 370 is formed.

[0097] When the upper cutter 500 is further moved downwards and thus at least a part of the first step 510 and at least a part of the second step 610 face each other in tight contact with each other, the sheets 30 are cut.

[0098] In the sheet cutting and fusion apparatus having the structure as shown in FIG. 7, the sheets 30 may be cut due to compression, shearing force, or melting by the first step 510 and the second step 610. Even though a sharp structure, such as a cutter, is not provided at each of the first step 510 and the second step 610, therefore, a smooth cut section may be formed after the sections of the cut sheets are cooled.

[0099] The first cutting surface 530, the first fusion portion 520, the second cutting surface 630, and the second fusion portion 620 may have the same temperature, and the temperature of the first cutting surface 530, the first fusion portion 520, the second cutting surface 630, and the second fusion portion 620 may be lower than the temperature of the first step 510 and the second step 610, such that the sheets are melted and separated from each other at the first step 510 and the second step 610 and such that the sheets, brought into tight contact with each other between the first cutting surface 530 and the second fusion portion 620 and between the second cutting surface 630 and the first fusion portion 520, are melted and adhered to each other, as described above.

[0100] For example, a sheet according to the present invention may be a sheet including a polyolefin-based material. As another example, the sheet may include a substrate made of a polyolefin-based material, including polyethylene and polypropylene, and an inorganic coating layer formed on one surface or opposite surfaces of the substrate. The inorganic coating layer may be constituted by a mixture of an inorganic material capable of improving heat resistance and a binder configured to bind particles of the inorganic material.

[0101] For example, the temperature of the first cutting surface 530, the first fusion portion 520, the second cutting surface 630, and the second fusion portion 620 may be set to a range of 80° C. to 150° C., and the temperature of the first step 510 and the second step 610 may be set to a range of 160° C. to 200° C.

[0102] The upper cutter 500 and/or the lower cutter 600 may be moved such that the first cutting surface 530 and the second cutting surface 630 overlap each other, and the sheets may be fused or cut due to compression, shearing force, or melting by the first fusion portion 520 and the second fusion portion 620.

[0103] In the case in which any one of the sheet cutting and fusion apparatuses shown in FIGS. 4 to 7 is used, the sheets may be fused when the sheets are disposed at any one of between the first cutting surface and the second cutting surface, between the first fusion portion and the second fusion portion, and between the first step and the second step.

[0104] When the upper cutter 100, 300, or 500 and the lower cutter, 200, 400, or 600 of the sheet cutting and fusion apparatus according to the present invention are continuously used, edges of the first step 110, 310, or 510, the first cutting surface 130, 330, or 530, the second step 210, 410, or 610, and the second cutting surface 230, 430, or 630 may become dull. In the case in which the edges are slightly worn, only the first step 110, 310, or 510, the first cutting surface 130, 330, or 530, the second step 210, 410, or 610, and the second cutting surface 230, 430, or 630 may be newly machined. In the case in which the sizes of the first step 110, 310, or 510 and the second step 210, 410, or 610 are reduced, whereby cutting and fusion according to the present invention are not simultaneously performed, the lower surface 140 or 340, the first connection portion 150, 350, or 550, the upper surface 240 or 440, and the second connection portion 250, 450, or 650 are also machined.

[0105] FIG. 8 is a view showing a unit cell manufactured using the sheet cutting and fusion apparatus according to the present invention.

[0106] Referring to FIG. 8, the unit cell is a bi-cell configured such that a first electrode 10, a sheet 30, a second electrode 20, a sheet 30, and a first electrode 10 are stacked. Sheets of one-direction outer peripheries of the bi-cell parallel to each other are thermally fused, whereby thermally fused portions 370 are formed.

[0107] When the bi-cell is transferred to a subsequent electrode manufacturing process, therefore, the state in which the sheets are stably attached to each other may be maintained, whereby it is possible to prevent short circuit or outbreak of fire due to exposure of the electrodes.

[0108] Those skilled in the art to which the present invention pertains will appreciate that various applications and modifications are possible within the category of the present invention based on the above description.

DESCRIPTION OF REFERENCE SYMBOLS

[0109] 10: First electrode [0110] 20: Second electrode [0111] 30: Sheet [0112] 40, 100, 300, 500: Upper cutters [0113] 110, 310, 510: First steps [0114] 120, 320, 520: First fusion portions [0115] 43, 130, 330, 530: First cutting surfaces [0116] 44, 140, 340: Lower surfaces [0117] 150, 350, 550: First connection portions [0118] 360: First corner [0119] 45: Inclined portion [0120] 50, 200, 400, 600: Lower cutters [0121] 210, 410, 610: Second steps [0122] 220, 420, 620: Second fusion portions [0123] 53, 230, 430, 630: Second cutting surfaces [0124] 54, 240, 440: Upper surfaces [0125] 250, 450, 650: Second connection portions [0126] 460: Second corner [0127] 370: Thermally fused portion [0128] W: Distance