Injection-Molded Battery Electrode Lamination Without Slitting Loss
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing methods for rechargeable battery electrodes face issues such as material loss, defects like wrinkles, and time loss due to changes in electrode specifications, particularly in the coating and slitting steps.
Innovation Solution
A method involving injection molding of a plate-shaped electrode sheet using an electrode mixture, followed by lamination with a metal substrate, which reduces material loss and defects by ensuring uniform thickness and preventing wrinkling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If coating step is used to apply active material slurry on metal substrate, then electrode plate is formed, but material loss occurs in active material slurry and metal substrate
Solution Approach 1:
The patent changes the physical state and application method of the electrode mixture from liquid slurry coating to solid injection molding. The electrode mixture is injected in a plasticized state and then cured to form a solid coating layer, eliminating the material loss associated with liquid slurry derivation while maintaining uniform coating quality through controlled injection parameters.
Solution Approach 2:
The patent replaces the mechanical coating process (slurry application and drying) with an injection molding process. The electrode mixture is injected through a die onto the metal substrate in a controlled manner, eliminating the need for separate coating and drying steps while reducing material loss and improving coating uniformity.
2Loss of substance
If notching step is used to cut metal substrate, then electrode plate shape is defined, but material loss occurs in active material and metal substrate
Solution Approach 1:
The patent merges the cutting operation into the injection molding process itself. The injection die is designed with the final electrode plate shape already defined, so the electrode mixture is injected directly into the desired shape without requiring separate notching or cutting steps, thereby eliminating material loss from punching operations.
Solution Approach 2:
The patent performs the cutting action preliminarily by designing the injection die with the final shape. The electrode mixture is injected directly into the mold cavity that defines the final electrode plate dimensions and shape, eliminating the need for subsequent cutting operations and the associated material loss.
3Manufacturing precision
If slitting step is used to cut electrode plate, then electrode plate is divided, but wrinkles occur in uncoated region increasing defect rate
Solution Approach 1:
The patent performs the shaping action preliminarily during injection molding. The electrode mixture is injected directly into the mold cavity that defines the final electrode plate shape, including any slits or divisions. This eliminates the need for subsequent slitting operations that cause wrinkles and defects in the uncoated regions.
Solution Approach 2:
The patent changes the process from mechanical slitting of cured electrodes to injection molding of the electrode mixture in the desired final shape. By controlling the injection parameters and mold design, the electrode is formed without wrinkles or defects in uncoated regions, while maintaining high production efficiency through continuous injection molding.
4Adaptability or versatility
If metal substrate width and coating die are changed to convert battery type, then different electrode specifications are produced, but time loss occurs due to changing equipment
Solution Approach 1:
The patent creates a universal injection molding system where a single injection device can produce different electrode specifications by changing only the injection die. The injection die is designed to be interchangeable while the base equipment remains the same, allowing rapid conversion between different battery types without extensive equipment changes or time loss.
Solution Approach 2:
The patent introduces dynamic adaptability through interchangeable injection dies. The system can quickly adapt to different electrode specifications by replacing the die, which is designed to accommodate various widths and shapes. This dynamic reconfiguration capability eliminates the need for permanent equipment modifications and reduces conversion time significantly.
Data Source
AI summary
A method of manufacturing an electrode of a rechargeable battery, the method including a first step of injection molding a plate-shaped electrode sheet in an injection mold with an electrode mixture that is input into an injection device, resulting in a molded electrode sheet, a second step of moving the molded electrode sheet onto a metal substrate and a third step of laminating the metal substrate and the molded electrode sheet.