Dry Electrode Roller Pairing for High Stretch in Compact Lines
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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 system.
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 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, allowing for improved stretch rates while minimizing the overall size of the apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple stretching rollers are added to the conventional apparatus, then the stretch rate of the free-standing film is improved, but the overall size of the apparatus increases
Solution Approach 1:
The patent merges the stretching function into the existing calendering rollers by creating a speed difference between them. The calendering rollers perform both calendering and stretching functions simultaneously, eliminating the need for separate stretching rollers and thereby reducing the overall apparatus size while maintaining improved stretch rate.
Solution Approach 2:
The patent applies dynamic speed control to the calendering rollers, where the linear velocity of at least one calendering roller differs from the others. This dynamic velocity difference creates the stretching effect without requiring additional static stretching rollers, thus resolving the contradiction between stretch rate improvement and apparatus size reduction.
2Productivity
If the linear velocity of shear rollers is increased to improve stretch rate, then the stretch rate improves, but the complexity of the apparatus increases
Solution Approach 1:
The calendering rollers are designed to perform multiple functions: both calendering the fine powder into free-standing film and stretching the film through differential speed rotation. This multi-functionality eliminates the need for separate stretching rollers and reduces apparatus complexity while achieving improved stretch rate.
Solution Approach 2:
The patent changes the operational parameters of the calendering rollers by setting different linear velocities for at least one roller compared to others. This parameter change enables the stretching function to be achieved through the existing calendering rollers without adding complex stretching mechanisms.
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 enhancing the stretch rate of the free-standing film, leading to improved manufacturing efficiency and reduced space requirements.
Implementation Method 1
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
Implementation Method 2
Each of the shear rollers may be configured to stretch the free-standing film together with one of the main rollers
Data Source
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.