Dry Electrode Calendering With Differential Roll Speed Lamination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dry electrode manufacturing processes for energy storage devices are inefficient and costly, requiring high shear and pressure, large equipment footprints, and complex operations, which hinder the production of high-quality, thin, and thick films with precise control over density and adhesiveness.
Innovation Solution
A multi-roll calendering system with individually controlled roll speeds and temperatures, allowing for the formation of dry electrode films that are not self-supporting but adhered to rolls, reducing pressure and equipment size, and enabling direct lamination onto current collectors, with adjustable thickness and density control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional dry electrode manufacturing processes are used, then high shear and pressure are applied to form electrodes, but this results in large equipment footprints and high operational costs
Solution Approach 1:
The patent changes the fundamental parameters of the manufacturing process by eliminating high shear and pressure requirements. The calendering system uses controlled pressure and temperature parameters to form electrodes, achieving sufficient film strength without the extreme conditions of traditional methods, thereby reducing equipment size and operational costs
Solution Approach 2:
The patent replaces the traditional high-shear mechanical mixing and pressing system with a calendering system that uses controlled rolling pressure and temperature. This substitution eliminates the need for large high-pressure equipment while achieving comparable or superior film quality with reduced equipment footprint
2Manufacturing precision
If complex manufacturing operations are used, then electrode density and adhesiveness can be controlled, but this increases operational complexity and costs
Solution Approach 1:
The patent achieves precise density and adhesiveness control through controlled changes in temperature and pressure parameters during calendering, rather than through complex multi-step operations. The controller adjusts roll temperatures and pressures to achieve target electrode properties, simplifying the process while maintaining high manufacturing precision
Solution Approach 2:
The system incorporates a controller that monitors and adjusts calendering parameters in real-time based on feedback from the manufacturing process, enabling precise control of electrode density and adhesiveness through automated parameter optimization rather than manual complex operations
3Manufacturing precision
If high pressure calendering is used, then electrode films can be formed, but this requires large equipment and high operational costs
Solution Approach 1:
The patent achieves precise film thickness control through controlled pressure application in the calendering rolls, using moderate pressure combined with temperature control to achieve the desired thickness and density without requiring extreme pressures, thereby reducing equipment size and operational costs while maintaining manufacturing precision
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 system facilitates the production of high-quality dry electrodes with improved film strength, adhesiveness, and electrical performance, reducing defects and operational complexity while minimizing factory space and personnel requirements.
Implementation Method 1
a first calendering roll and a second calendering roll, the second calendering roll configured to form a first nip between the first calendering roll and the second calendering roll, the first nip configured to receive the dry electrode material from the first dry electrode material delivery system and form a dry electrode film from the dry electrode material
Implementation Method 2
the controller configured to control a rotational velocity of the second calendering roll to be greater than a rotational velocity of the first calendering roll
Data Source
AI summary
A system and methods for manufacturing a dry electrode for an energy storage device are disclosed. The system includes a first dry electrode material delivery system configured to deliver a dry electrode material, a first calendering roll, a second calendering roll, and a controller. The second calendering roll is configured to form a first nip between the first calendering roll and the second calendering roll. The first nip is configured to receive the dry electrode material from the first dry electrode material delivery system, and form a dry electrode film from the dry electrode material. The controller is configured to control a rotational velocity of the second calendering roll to be greater than a rotational velocity of the first calendering roll. 62385256