Battery Electrode Lead Tab Flatness During Cutting
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Solution Overview
Problem
Conventional methods for manufacturing battery electrodes often result in deformed or wrinkled lead tabs during the cutting process, which affects the quality of the electrodes and the subsequent battery performance.
Innovation Solution
A method where the electrode lead tabs are integrally formed within the non-application parts of the electrode base materials during the cutting process, ensuring that the collector surfaces of both the application and non-application parts remain in the same plane, preventing deformation and wrinkling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lead tab formation part is not held between strippers during cutting, then the cutting process can be simplified, but the lead tab becomes deformed or wrinkled
Solution Approach 1:
The patent applies preliminary action by extending the active material layer onto the lead tab formation part before cutting occurs. This pre-positioned material layer acts as a support structure that prevents deformation during the cutting process, eliminating the need for complex stripper mechanisms while ensuring the lead tab remains flat and undistorted.
2Weight of moving object
If the collector is made thinner to reduce weight, then the battery energy density improves, but the mechanical strength and handling difficulty worsen
Solution Approach 1:
The patent applies parameter changes by modifying the physical state and distribution of the active material layer. By extending this layer onto the lead tab formation part, the system changes from a thin, vulnerable collector structure to a reinforced composite structure where the active material layer provides additional mechanical support, enabling the use of thinner collectors without sacrificing strength.
3Manufacturing precision
If the active material layer is extended onto the lead tab formation part, then the lead tab remains flat during cutting, but the cutting blade path becomes more complex
Solution Approach 1:
The patent applies the taking out principle by separating the support function from the cutting mechanism. Instead of making the cutting blade system complex to accommodate the lead tab formation part, the solution extracts the support function and assigns it to the active material layer, which naturally extends onto the lead tab area. This simplifies the cutting mechanism while maintaining precision.
Data Source
AI summary
Disclosed is a method of manufacturing a battery electrode in which a positive electrode lead tab and a negative electrode lead tab each of which is integrally formed with a collector formed of a metal foil and has excellent characteristics. The method includes separating a battery electrode having a desired size from a strip-shaped electrode in which an active material is intermittently applied onto a collector. The strip-shaped electrode includes an n-th application part, an n-th non-application part adjoining the n-th application part, and an (n+1)-th application part that adjoins the n-th non-application part on an opposite side at which the n-th application part adjoins the n-th non-application part (n is a positive integer). The battery electrode is cut out from the strip-shaped electrode, including at least the n-th application part, n-th non-application part, and (n+1)-th application part.