Dry Electrode Roller Layout for Compact Film Stretching
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Solution Overview
Problem
Conventional apparatuses for manufacturing dry electrodes for rechargeable batteries are large due to the need for multiple rollers, including stretching rollers, which increases the overall size and complexity of the manufacturing process.
Innovation Solution
The apparatus includes a feeder for supplying fine powder, a series of main rollers for calendering the powder into a free-standing film, and a set of shear rollers positioned adjacent to the main rollers to stretch the film, with the shear rollers having smaller diameters and higher linear velocities than the main rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If multiple stretching rollers are used to stretch the free-standing film, then the stretching function is improved, but the overall size of the apparatus increases
Solution Approach 1:
The patent combines the stretching function with the calendering function by integrating stretching rollers into the calendering section. The stretching rollers are positioned between the calendering rollers and share the same space, allowing simultaneous calendering and stretching operations without requiring separate stretching sections, thus minimizing the overall apparatus size while maintaining effective stretching capability
Solution Approach 2:
The patent utilizes the radial dimension of the rollers by positioning stretching rollers adjacent to calendering rollers in a direction crossing the film travel direction. This spatial arrangement allows stretching to occur in a different dimensional plane, enabling multiple functions within the same footprint and reducing the linear length of the apparatus
2Productivity
If multiple rollers are used for calendering and stretching, then the manufacturing function is improved, but the device complexity increases
Solution Approach 1:
The stretching rollers are designed to perform multiple functions: they serve as both stretching elements and support structures for the film during calendering. Each stretching roller works in conjunction with a calendering roller to simultaneously compress and stretch the film, reducing the total number of rollers needed while maintaining manufacturing efficiency
Solution Approach 2:
The calendering section is divided into multiple zones with different roller pairs, where each zone performs both calendering and stretching functions. This segmentation allows different sections to optimize for specific requirements (e.g., different stretching ratios or calendering pressures) without requiring entirely separate systems, thus managing complexity through functional division
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 configuration minimizes the overall size of the apparatus while improving the stretch rate of the free-standing film, enhancing the manufacturing efficiency and reducing the physical footprint of the equipment.
Implementation Method 1
a plurality of main rollers sequentially disposed in a first direction and configured to calender the fine powder supplied from the feeder into a free-standing film
Implementation Method 2
a plurality of shear rollers adjacent to the plurality of main rollers in a second direction crossing the first direction, wherein the plurality of main rollers and the plurality of shear rollers are configured such that the free-standing film is interposed between the main rollers and the shear rollers
Data Source
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AI summary
An apparatus for manufacturing a dry electrode may include a feeder configured to supply fine powder, a plurality of main rollers sequentially disposed in a first direction and configured to calender the fine powder supplied from the feeder into a free-standing film, and a plurality of shear rollers adjacent to the plurality of main rollers in a second direction crossing the first direction. The plurality of main rollers and the plurality of shear roller are configured such that the free-standing film is interposed between the main rollers and the shear rollers.