Battery Electrode Metallic Carrier Rigidity via Perpendicular Structure
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Solution Overview
Problem
Current methods for producing battery electrodes are inefficient, leading to increased material and weight costs, reduced manufacturing speed, and decreased robustness, particularly in the production of high-voltage batteries for electric vehicles.
Innovation Solution
A method involving a metallic carrier with a structure introduced perpendicularly to its plane, which increases rigidity and prevents bending or torsion, allowing for the application of an active material layer without additional weight or material, using a roller to incorporate the structure and simplify the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional flat metallic carrier is used for battery electrodes, then material costs and weight are reduced, but the electrode lacks rigidity and is prone to bending or torsion during processing
Solution Approach 1:
The patent introduces a three-dimensional structure (ridges and grooves) into the otherwise two-dimensional flat metallic carrier. This dimensional transformation creates geometric reinforcement that increases rigidity and prevents bending/torsion without requiring additional material thickness or weight, directly resolving the contradiction between strength and weight.
2Reliability
If the metallic carrier is made more rigid to prevent bending, then processing robustness increases, but material costs and weight increase
Solution Approach 1:
The geometric structure adds vertical dimensionality (height) to the metallic carrier surface, creating rigid ridges and grooves that provide mechanical stability during processing. This achieves enhanced reliability without increasing overall carrier weight, as the reinforcement comes from shape rather than material quantity.
Solution Approach 2:
The patent creates a composite structure where the metallic carrier combines a flat base layer with a three-dimensional geometric pattern. This composite architecture integrates structural reinforcement into the carrier itself, providing processing robustness while maintaining low weight through efficient material distribution.
3Reliability
If additional structural elements are added to increase rigidity, then manufacturing robustness improves, but device complexity increases
Solution Approach 1:
The metallic carrier is segmented into distinct regions of ridges and grooves, creating a modular geometric pattern. This segmentation provides structural reinforcement through repeated simple units rather than a single complex feature, reducing manufacturing complexity while maintaining overall rigidity and reliability.
Solution Approach 2:
The geometric structure creates a porous-like pattern of ridges and grooves on the metallic carrier surface. This open structured design provides mechanical reinforcement while maintaining material efficiency and simplifying manufacturing compared to solid thick sections, balancing robustness with structural simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the production process, reduces material and weight costs, increases manufacturing speed, and enhances the robustness of electrodes, resulting in improved power density and stability of high-voltage batteries.
Implementation Method 1
a structure which is introduced into the carrier perpendicular to the plane of extension of the carrier is provided, wherein the structure increases a rigidity of the carrier and prevents bending or torsion of the carrier
Data Source
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AI summary
The invention relates to a method (36) for manufacturing an electrode (16) of a battery (14). A planar metallic support (24) arranged in an expansion plane (27) is provided, and a structure (34) perpendicular to the expansion plane (27) is incorporated into an edge (32) of the support (24). The invention further relates to an electrode (16) of a battery (14) and a device (38).