# US 2026/0100398 A1 · Apparatus, system and method for continuous singulated electrodes > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2026/0100398 A1 - Document ID: US20260100398A1 - Status: Published application - Kind: A1 - Application number: 19/351,800 - Filed: 2025-10-07 - Published: 2026-04-09 - Earliest claimed: 2024-10-07 - Applicants: DW Energy LLC - Inventors: Dan Alexander Sturges; Brady L. Byers; Christopher E. Barns; Derek Graham Aqui; Gautam Dhar; Alex Montes - Web page: https://patentgrep.com/patent/US20260100398A1 ## CPC - H01M 10/0404: {Machines for assembling batteries} - H01M 10/0413: {Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes} - H01M 10/0459: {Cells or batteries with folded separator between plate-like electrodes} - Y02E 60/10: Energy storage using batteries - Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract The present disclosure relates to apparatus, systems, and methods for continuous motion battery stacking by picking singulated electrodes and separators and placing each into a stack secured on a downstream process of a battery stacking system. The continuous singulated battery stacking system includes a rotating electrode transfer device integrated with a deformable shoe mechanism for handling electrodes during high-precision stacking processes and adjusting dynamically to the shape of the in-feed and downstream conveying surfaces, allowing for smooth, continuous contact during pick-and-place operations. This flexibility ensures consistent pressure distribution and minimizes the risk of misalignment or damage during transfer. Adapting in real time, the deformable shoe enhances alignment, reduces machine wear, and maintains high accuracy in stacking processes, especially for sensitive materials like lithium foil or separators. This innovation optimizes high-speed stacking, contributing to improved battery manufacturing efficiency and reliability. ## Claims ### Claim 1 An apparatus for continuously stacking singulated electrodes and separators in a battery stacking system, the apparatus comprising: a first in-feed conveyor configured to transport singulated anode sheets from an upstream singulations region; a second in-feed conveyor configured to transport singulated cathode sheets from an upstream singulations region; a third in-feed conveyor configured to transport singulated separator sheets from an upstream singulation region; a transfer device having a gripping shoe, wherein the transfer device is configured to transfer an anode, a cathode, and a separator from the respective first in-feed conveyor, second in-feed conveyor, and third in-feed conveyor to a picking prism using the gripping shoe; wherein the picking prism is further configured to pick the anode, the cathode, and the separator from the gripping shoe of the rotating transfer device using one of at least three gripping shoes coupled to the picking prism. ### Claim 2 (depends on 1) The apparatus, according to claim 1, wherein the transfer device is a rotating transfer device and the gripping shoe is a deformable vacuum-assisted gripping shoe; and wherein the rotating transfer device is adapted to alternately transfer an anode and a cathode to the rotating picking prism. ### Claim 3 (depends on 2) The apparatus, according to claim 2, wherein the rotating transfer device has at least two rotating arms. ### Claim 4 (depends on 2) The apparatus, according to claim 2, further comprising a quality inspection device adapted to inspect the cathodes, the separators, and the anodes before they are transferred to the rotating transfer device. ### Claim 5 (depends on 2) The apparatus, according to claim 2, further comprises a quality inspection device adapted to inspect the cathodes, the separators, and the anodes before they are transferred to the rotating picking prism. ### Claim 6 (depends on 1) The apparatus, according to claim 1, wherein each of the first in-feed conveyor, the second in-feed conveyor, and the third in-feed conveyor further comprises an alignment device configured to align the electrodes and separators while they are on the conveyor. ### Claim 7 (depends on 2) The apparatus, according to claim 2, wherein each of the rotating transfer devices comprises an alignment device configured to align the electrodes and separators while they are continuously in motion and transferred to the rotating picking prism. ### Claim 8 A system for continuously stacking singulated electrodes and separators in a battery stacking system, comprising: a first in-feed conveyor configured to transport singulated anode sheets from an upstream singulations region; a second in-feed conveyor configured to transport singulated cathode sheets from an upstream singulations region; a third in-feed conveyor configured to transport singulated separator sheets from an upstream singulation region; a transfer device having at least one vacuum-assisted gripping shoe, wherein the transfer device is configured to transfer an anode, a cathode, and a separator from the respective first in-feed conveyor, second in-feed conveyor, and third in-feed conveyor to a rotating picking prism using the at least one vacuum-assisted gripping shoe; wherein the rotating picking prism is further configured to pick the anode, the cathode, and the separator from the at least one vacuum-assisted gripping shoe of the transfer device using one of at least three gripping shoes coupled to the rotating picking prism. ### Claim 9 (depends on 8) The system, according to claim 8, wherein the transfer device is adapted to alternately transfer an anode and a cathode to the rotating picking prism. ### Claim 10 (depends on 8) The system, according to claim 8, wherein the transfer device has one position in which it is simultaneously gripping an anode and releasing a cathode and one position in which it is simultaneously gripping a cathode and releasing an anode. ### Claim 11 (depends on 8) The system, according to claim 8, further comprises quality inspection devices adapted to inspect the cathodes, the separators, and the anodes before they are transferred to the transfer device or to the rotating picking prism. ### Claim 12 (depends on 8) The system according to claim 8, wherein each of the first in-feed conveyor, the second in-feed conveyor, and the third in-feed conveyor further comprises an alignment device configured to align the electrodes and separators while they are on the conveyor. ### Claim 13 (depends on 8) The system, according to claim 8, wherein each of the transfer devices comprises an alignment device configured to align the electrodes and separators while they are continuously in motion and transferred to the rotating picking prism. ### Claim 14 (depends on 8) The system, according to claim 8, wherein the at least three gripping shoes coupled to the rotating picking prism further comprise a surface adapted to adhere an electrode to its surface via vacuum, wherein the surface has a plurality of vacuum zones that can be individually controlled; a processor further configured to track an angular position of the plurality of vacuum zones; determine that the angular position of at least one of the plurality of vacuum zones has reached a predetermined angular position; and deactivate at least one of the plurality of vacuum zones when the predetermined angular position is reached. ### Claim 15 (depends on 14) The system according to claim 14, wherein the rotating picking prism is further adapted to push on the electrode or separator with an air jet when the vacuum is turned off. ### Claim 16 A battery stacking system, comprising: a first battery stacking station adapted to receive at least one singulated anode, at least one singulated cathode, and at least one singulated separator material; a second battery stacking station adapted to receive at least one singulated anode, at least one singulated cathode, and at least one singulated separator material; wherein each of the battery stacking stations is adapted to be positioned at a battery stacking position and a battery removal position; and a removal device, adapted to remove a battery stack from either the first or second battery stacking station when it is in a battery removal position. ### Claim 17 (depends on 16) The battery stacking system, according to claim 16, wherein the first battery stacking station and second battery stacking station further comprise: a vacuum source that is fluidly coupled to the first battery stacking station and the second battery stacking station, wherein the vacuum source is adapted to exert a suction force on the battery stack that encircles the battery stack. ### Claim 18 (depends on 16) The battery stacking system according to claim 16, wherein each battery stacking station (a) is positioned on a mechanical transportation device, and is thereby adapted to move along at least two axes that are perpendicular to each other and (b) includes a movable side wall. ### Claim 19 A method for battery stacking and removal, comprising: stacking anodes, cathodes, and separator material on a first battery stacking station at a stacking position until a first battery stack has been produced; moving the first battery stacking station to a removal position and moving a second battery stacking station to the stacking position; stacking anodes, cathodes, and separator material on the second battery stacking station until a second battery stack has been produced; removing the first battery stack from the first battery stacking station. ### Claim 20 (depends on 19) The method according to claim 19, wherein the first battery stack is removed from the first battery stacking station while the second battery stack is being stacked on the second battery stacking station. ### Claim 21 (depends on 18) The method according to claim 18, further comprising moving the second battery stacking station to the removal position and the first battery stacking station back to the stacking position. ### Claim 22 (depends on 20) The method according to claim 20, wherein the first battery stacking station is moved to the battery removal position at the same time the second battery stacking station is moved to the battery stacking position, and vice versa.