Judgment Basis and Mechanical Analysis of Current Collector Failure in the Winding Process of a Lithium-Ion Battery

The winding process is one of the essential processes in the manufacturing of lithium-ion batteries (LIBs). Current collector failure frequently occurs in the winding process, which severely increases the production cost and reduces production efficiency. In order to solve this problem, we first analyze the relationship between different process parameters and the failure of the current collector, and put forward the standard to determine the failure of the current collector. Moreover, we conducted tensile experiments to validate the differences in the mechanical performance of the current collector under different thicknesses. Finally, the circumferential stress and strain of the current collector winding were calculated using finite element analysis. The accuracy of the proposed criterion for determining current collector failure was verified through experimental measurements of stress and strain. The results demonstrate that the criterion proposed in this study can accurately calculate the maximum stress during the current collector winding process, providing a powerful tool for addressing the issue of current collector failure in the winding process.