Battery Electrode Substrate Sheet with Integrated Defect Sign Marking
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Solution Overview
Problem
Existing battery electrode manufacturing processes face inefficiencies due to coating thickness unevenness, leading to increased material waste and additional processing steps, as defect signs on metal foils require separate marking and protective films, resulting in unnecessary material discard and complex production processes.
Innovation Solution
A battery electrode substrate sheet with a strip-shaped collector, where an insulating protective film is formed along the electrode active material coating, and defect sign parts are indicated on the film, allowing for efficient identification and exclusion of defective areas without additional members, using ultraviolet curing composition and inkjet coating for precise defect indication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate defect sign marking means is used on the metal foil, then defective parts can be identified, but the device complexity and processing steps increase
Solution Approach 1:
The patent combines the defect sign marking function with the insulating protective film formation process. The insulating protective film is applied to the entire metal foil surface, and defective regions are identified by the absence or difference in this film, eliminating the need for separate marking operations and reducing device complexity while maintaining defect identification accuracy
Solution Approach 2:
The insulating protective film serves dual purposes: it provides electrical insulation for battery safety and simultaneously acts as a defect indicator. Regions without the film indicate defective areas, allowing one component to perform multiple functions and reduce overall system complexity
2Reliability
If a defect sign part is formed on the collector, then defective areas can be marked, but the collector width must be increased to provide gaps between the defect sign and insulating protective film
Solution Approach 1:
The defect indication is merged into the insulating protective film pattern itself. The film is selectively applied or removed to create visible defect markers, eliminating the need for additional space and gap requirements between separate marking components
Solution Approach 2:
The defect information is copied onto the insulating protective film through selective application or removal patterns. The film pattern replicates the defect locations, allowing defect identification without requiring additional physical space for separate marking structures
3Reliability
If separate marking and protective film formation steps are used, then defect detection is achieved, but the productivity decreases due to additional processing steps
Solution Approach 1:
The patent merges the defect marking function into the insulating protective film formation step. By using the film's presence, absence, or pattern as the defect indicator, the process eliminates redundant operations and improves productivity while maintaining reliable defect detection
Solution Approach 2:
The insulating protective film performs both its primary insulation function and serves as a defect detection mechanism. This multi-functionality reduces the total number of processing steps required, thereby increasing production efficiency without compromising defect detection accuracy
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 reduces material waste, simplifies defect identification, and streamlines production by integrating defect indication into the insulating protective film, enabling effective cutting of defect-free electrodes with reduced material usage and processing steps.
Implementation Method 1
an insulating protective film formed on an electrode active material non-coating surface of the collector so as to extend along the coating film in the longitudinal direction
Implementation Method 2
a defect sign part that indicates a portion at which a defective part of the coating film exists is formed on the insulating protective film
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
To provide a battery electrode substrate sheet capable of reducing a waste part, in which a defect part is included, of an electrode active material coating film coated on a collector. A battery electrode substrate sheet includes a strip-shaped collector 101, an electrode active material coating film 103 formed on the collector in a longitudinal direction thereof, and an insulating protective film 107 formed on an electrode active material non-coating surface of the collector so as to extend along the coating film in the longitudinal direction thereof. A defect sign part 105 that indicates a portion at which a defective part 104a of the coating film exists is formed on the insulating protective film 107.