Stepped Roll Boundary Stretching for Electrode Sheet Wrinkle Control
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Solution Overview
Problem
Wrinkles occur in electrode sheets during manufacturing due to differences in elongation rates between the uncoated and coated regions of the current collector, which are not easily stretched in the uncoated and coated portions, which are not easily stretched in the uncoated portions, leading to issues in tab formation.
Innovation Solution
A stepped roll pressing method and apparatus with a stepped roll pressing method and apparatus that includes a stepped roll-pressing apparatus and method that includes a stepped roll pressing apparatus and method that includes a stepped roll, which includes a stepped roll, which includes a stepped roll pressing apparatus and method that uses a stepped roll with a larger diameter at the boundary regions of the uncoated portions with the active material layer, reducing the difference in elongation rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a pair of elastic rolls is used to press the uncoated portion during roll-pressing, then the uncoated portion can be stretched while preventing breakage, but wrinkles may occur in the electrode sheet due to difference in elongation rate between boundary region and other regions
Solution Approach 1:
The stepped roll has a locally larger diameter at the part coming into contact with the boundary region of the unformed portion with the active material layer compared to other parts. This local variation in roll diameter creates differential pressing force that addresses the elongation rate difference between regions, preventing wrinkles while maintaining breakage prevention.
2Ease of manufacture
If uniform pressing is applied across the electrode sheet during roll-pressing, then the pressing process is simple, but the difference in elongation rate between boundary region and other regions causes wrinkles
Solution Approach 1:
The stepped roll provides non-uniform pressing force with a locally larger diameter at the boundary region contact point. This design maintains relative manufacturing simplicity while creating the necessary differential elongation control to prevent wrinkles at the boundary between unformed and coated portions.
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
The stepped roll pressing method effectively reduces wrinkles in the electrode sheet by locally stretching the current collector at the boundary regions, ensuring uniform elongation and improving tab formation.
Implementation Method 1
The stepped roll has a larger diameter locally at a part coming into contact with a boundary region of the unformed portion with the active material layer than other parts of the stepped roll coming into contact with other regions of the electrode sheet
Data Source
AI summary
An electrode sheet manufacturing method includes a stepped roll pressing step of conveying an electrode sheet while pressing the electrode sheet onto a stepped roll that has a larger diameter at a part coming into contact with a boundary region of an uncoated portion with an active material layer than other parts coming into contact with other regions of the electrode sheet.