Rechargeable Battery Electrode Thickness Layout for Multi-Row Compression
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Solution Overview
Problem
The existing methods for manufacturing rechargeable battery electrodes face productivity issues due to damage caused by the difference in elongation between coated and uncoated regions during compression, leading to decreased productivity as the number of plates to be compressed increases.
Innovation Solution
The electrode design includes a substrate with pressurized regions having active material layers with varying thicknesses, where the thicker portion is compressed primarily, and the thinner portion is positioned between the coated and uncoated regions, allowing for simultaneous compression without separating each active material column, thereby minimizing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If compression is performed after applying active material on multiple rows without separating each electrode, then productivity is improved, but electrode plate damage occurs due to difference in elongation between coated and uncoated regions
Solution Approach 1:
The active material layer is designed with non-uniform thickness, featuring a first portion with greater thickness than a second portion. This local quality variation allows the thicker first portion to accommodate compression-induced elongation while the thinner second portion maintains structural integrity at transition zones, enabling multi-row compression without electrode plate damage.
Solution Approach 2:
The active material is applied in a preliminary multi-row pattern on the substrate before compression is performed. This preliminary arrangement allows subsequent compression of multiple rows simultaneously without requiring separation, thereby improving productivity while the controlled thickness distribution prevents damage during this compression process.
2Reliability
If slitting is performed after applying active material to separate each electrode, then electrode plate damage is minimized, but productivity decreases due to increased number of compression processes required
Solution Approach 1:
By creating local quality variation in the active material layer thickness, the invention enables the entire multi-row structure to withstand compression uniformly without requiring slitting to separate individual electrodes. The thicker first portion absorbs compression stress while the thinner second portion prevents excessive elongation at boundaries, allowing all rows to be compressed together in one operation.
Solution Approach 2:
The invention merges multiple electrode rows into a single continuous structure with varying thickness that can be compressed simultaneously. Instead of separating and compressing each electrode individually, the multi-row active material layer is compressed as one integrated unit, significantly improving productivity while maintaining electrode integrity through the controlled thickness distribution.
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 design minimizes damage to the electrode plate by reducing the pressure difference between coated and uncoated regions during compression, maintaining electrode integrity even when multiple rows of active material layers are compressed together.
Implementation Method 1
a first pressurized region and a second pressurized region
Implementation Method 2
minimizes damage to the electrode plate by reducing the pressure difference between coated and uncoated regions during compression
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An exemplary embodiment of the present disclosure provides a rechargeable battery electrode (11, 12, 700, 701, 703, 704) including: a substrate (70) configured to have a first pressurized region and a second pressurized region; and an active material layer (71, 72, 73, 74, 75, 76, 77) configured to have a first portion (D1) formed in the first pressurized region and a second portion (D2) formed in the second pressurized region, wherein a thickness of the first portion (D1) is thicker than a thickness of the second portion (D2).