Electrode Rolling/Calendering TRIZ Cases

See how integrated heating, cooling, and insulation in powder hoppers achieve ±5°C temperature

A non-spherical cross-linked polymer binder improves slurry dispersion and adhesion, enabling high-solids anode coating with less solvent.

Laser-guided cutting on movable support segments improves electrode singulation, positioning, and process reliability in battery cell assembly.

A PVdF copolymer catholyte with ionic liquid and plastic crystal enables dense solid-state cathodes with better high-voltage stability and cycling.

Folded or rolled current collector edge strips create stable contact plate interfaces, lowering internal resistance and short-circuit risk.

A rotating scoop hopper uses gravity and automatic compensation to keep calender powder feed uniform without fibrillation or blockage.

Low-surface-area LFP secondary particles improve slurry miscibility and coating uniformity in LFP-ternary cathodes, boosting battery performance.

Through-holes in the active material layer improve component uniformity, flexibility, and high-rate performance in high-loading lithium batteries.

Arc-shaped wrinkles keep stacked electrode tabs uniform in thickness, enabling stable bonding to collecting members and reducing tab breakage.

Adjustable sub-rolls and a press portion apply localized tension to uncoated electrode areas, preventing wrinkles and improving line productivity.

Low-shear kneading and pulverization reduce active material damage and preserve binder fibrils for flexible, mass-producible dry electrodes.

A recessed stepped pouch case and uncoated electrode zones keep a foldable cell aligned, limiting separation, damage, and capacity loss.

Pressure sensing on the passing roller enables real-time electrode plate calendering checks, reducing scrap from under- or over-pressing.

Dual-sided infrared assemblies heat both electrode sheet surfaces evenly, improving thick-sheet drying while reducing warping, cracking, and overbaking.

Staged rolling limits thickness change after the first pass, preventing LFP cathode delamination while preserving density and low resistance.

Varying electrode porosity, thickness, and loading offsets temperature-driven reaction imbalances to limit Li-Ion cell degradation during fast charging.

Continuous winding and bending of unit electrode layers removes cutting and manual lamination, boosting battery assembly speed and lowering cost.

Variable-area grooves in a secondary battery electrode improve electrolyte permeation while limiting ejection during charge-discharge cycling.

Long-side current collectors shorten electron paths in stacked cells, reducing internal resistance and improving current and heat distribution.

Pre-drying grooves in a gas-phase-retained thick electrode coating improve flexibility, reduce cracking, and protect battery quality.

Conductive contact strips on process rollers measure local web resistance in-line, enabling defect detection and coating uniformity control.

Through-apertures in the current collector and active layer limit electrode elongation during nail penetration, reducing short-circuit ignition risk.

Dry electrodes with a fiberized cathode binder and granular anode avoid solvent drying defects, lowering resistance and improving fast-charge life.

Attaching reinforcing film before winding strengthens electrode plates or separators, simplifies cell production, and improves winding efficiency.

Room-temperature compression bonding of lead and carbon forms electrodes that better withstand voltage fluctuation and fast charge-discharge cycling.

Controlled first and second rolling creates dual-porosity cathode layers that improve structural stability, capacity, and cycle life.

Controlled slurry coating below 40 °C helps positive electrode additives resist deformation, preserving lithium secondary battery capacity and life.

Multiple detection members inspect electrode sheets before and after drying to catch dimensional distortion and surface defects before rewinding.

Dry electrode preparation uses a fiberized cathode binder and anode granules to avoid solvent-driven defects, lowering resistance and improving cycle life.

Patterned pre-lithiation diffuses lithium into the anode and adds line-shaped concaves to retain electrolyte, reducing initial loss and improving cell performance.

Heating and then cooling the uncoated electrode region reduces rebound, balances extensibility, and prevents rolling wrinkles.

Predictive adjustment of compression and bend loads keeps secondary battery electrode thickness stable during line acceleration and deceleration.

A crowned traversing roller avoids uncoated regions during electrode transport, reducing residual stress, wrinkles, and breakage.

Elastic roller layers and deformation prevention rollers enable uniform electrode stack pressing, reducing impact damage and improving tab sealing.

A two-layer binder gradient boosts membrane strength while preserving ionic conductivity and reducing negative-electrode side reactions.

Maps calender roller dents in place and repairs them by local material deposition, avoiding roller removal and production downtime.

A multimodal particle size mix lets gel electrode precursors reach higher active loading with lower forming force and less solvent-cast energy.

Automatic roll cleaning switches between operating and stopped modes to remove contaminants without slowing electrode production.

Controlled oxide-film thickness on cathode particles suppresses electrolyte decomposition while limiting resistance rise and short-circuit heat.

Level-sensed multi-feeder control keeps dry electrode mixture flowing on the roll press, limiting buildup, thickness variation, and material loss.

Edge rolling with paired rollers redistributes stress after pole piece slitting, reducing wrinkles, scrap, and battery safety risk.

A stepped transfer roller with an inclined section equalizes elongation between coated and uncoated electrode regions to prevent skew and damage during slitting.

Roll maps link encoder and controller data to defect positions, cutting inter-process loss and improving electrode quality control.

Compressed electrode measurement data is modified and joined with cell IDs to preserve roll map traceability without storing full raw data.

Pre-wetting a cleaning cloth with supplied liquid keeps press rolls clean during idle and running states, helping maintain electrode quality.

Near-infrared spectra and differential-mean ML predict electrode adhesion non-destructively, enabling real-time battery coating quality checks.

Matched dual pressure rolls follow the coating step height to prevent wrinkles and folds on electrode non-coating parts.

Single-particle high-nickel cathodes use two-stage sintering to limit rolling cracks, fine powder, and electrolyte side reactions.

Different electrolyte additive use in high- and low-nickel cathode layers cuts side reactions, gas generation, and resistance at high temperature.

Differential roll speeds form and laminate dry electrode films with lower pressure, improving thickness control, adhesiveness, and factory footprint.

A magnetic powder clutch holds torque on the rotating shaft to stop turret sliding, improving positioning accuracy and stability.

Pressure-assisted firing densifies the electrode layer and preserves ion conduction at the solid electrolyte interface for higher battery capacity.

Laser-formed pores correct non-uniform electrode sheet porosity, improving electrolyte wettability and ion transport in secondary batteries.

Differential roller speeds apply shear in dry electrode forming to improve binder adhesion, control thickness, and avoid solvent drying.

An angled strip terminal and bending roller reduce sagging, save internal battery space, and protect the electrode assembly.

Multi-stage drying briefly above the PVDF binder melting point cuts residual moisture while preserving electrode adhesion and productivity.

A dual-polymer gel electrode precursor improves electronic conductivity while preserving fluidity, enabling higher active-material loading with lower energy processing.

Single-walled carbon nanotubes form conductive links around silicon anode particles, limiting resistance growth and preserving cycle life.

A foam-and-solid metal current collector adds local reinforcement to resist winding damage while preserving battery energy storage performance.

Unequal roller diameters enable dry electrode lamination with better density uniformity, gap control, and fewer wrinkles and defects.

A matrix-distributed metal anode enables open-air or dry-room assembly while improving alkali metal deposition, interface resistance, and cycling.

Controlled pore size and uniform binder distribution in a dry electrode cut diffusion resistance and avoid drying defects for better high-rate charging.

A dense sulfur cathode paired with low-solubility electrolyte cuts electrolyte loading, limits shuttle effects, and improves cell integrity.

Increasing roller diameters and controlled gaps thin solvent-free electrode films below 80 μm for high-nickel lithium-ion cathodes.

Photon irradiation ejects electrons from a lithium reservoir, driving graphite anode prelithiation while reducing first-cycle loss and preventing copper corrosion.

A steep 80-90° electrode edge and laser ablation remove slurry sliding, improving thickness uniformity, adhesion, and cycle stability.