Compound Sheet Cutting Roll for Electrode Window Formation
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Solution Overview
Problem
Conventional apparatuses for manufacturing power storage apparatuses, such as secondary batteries and capacitors, face limitations in increasing their capacity and maintaining the quality of the electrode sheets.
Innovation Solution
A molding apparatus and method that uses a support roll and a molding roll with a cutting jig and removal pad to partially cut a compound sheet, forming through holes and window portions, allowing for increased electrode compound coverage and reduced current collector exposure, thereby enhancing the capacity and safety of the power storage apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional apparatuses are used to manufacture electrode sheets, then the manufacturing process is simple, but the capacity of power storage apparatuses cannot be increased
Solution Approach 1:
The molding roll is divided into multiple independent molding units, each capable of forming window portions at different positions. This segmentation allows the apparatus to process multiple areas of the compound sheet simultaneously, increasing capacity without requiring multiple separate apparatuses.
Solution Approach 2:
The molding roll serves multiple functions: it acts as a support for the compound sheet, provides cutting edges for forming window portions, and includes removal pads for extracting electrode compound. This multi-functionality increases apparatus capacity while avoiding the need for separate devices for each operation.
2Productivity
If more electrode compound is used to increase capacity, then the capacity of power storage apparatus increases, but the risk of separator damage increases
Solution Approach 1:
Window portions are formed at specific locations where electrode compound is removed to expose the current collector plate. This local modification allows electrode compound to be concentrated in critical areas for high capacity while maintaining separator integrity in other regions by providing proper bonding surfaces.
Solution Approach 2:
Window portions are formed in advance during the molding process, creating predetermined exposure areas on the current collector plate. This preliminary action ensures that when electrode compound is applied, it bonds properly to the current collector at these predetermined locations, preventing separator damage while maximizing capacity.
3Reliability
If conventional molding methods are used, then the manufacturing process is simple, but the bonding of current collection leads is insufficient
Solution Approach 1:
The molding roll includes multiple independent molding units positioned at different locations, each capable of forming window portions for current collection lead bonding. This segmentation allows simultaneous bonding at multiple locations, improving overall bonding reliability without requiring sequential processing.
Solution Approach 2:
The window portions formed by the molding units act as intermediary bonding surfaces between the electrode compound and the current collector plate. These exposed areas provide optimal surfaces for current collection lead attachment, enhancing bonding reliability.
Data Source
AI summary
A molding apparatus for a compound sheet includes: a support roll that supports a compound sheet on a circumferential surface of the support roll; and a molding roll that includes a cutting jig having a frame shape and a removal pad disposed in a frame of the cutting jig and rotates together with the support roll, the circumferential surface of the molding roll facing the circumferential surface of the support roll at a predetermined interval. The molding roll presses the cutting jig against the compound sheet to cut the compound sheet partially and attaches a cut portion to a surface of the removal pad to remove the cut portion.