Dry Electrode Lamination Using Unequal Rollers for Density Uniformity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrode manufacturing processes face challenges in uniformly controlling density and reducing defects due to variations in pressure application during rolling, particularly in dry lamination methods, which lack control over gap and pressure during lamination.
Innovation Solution
An electrode manufacturing apparatus and method utilizing rollers with different diameters to process a dry electrode composition into a sheet form, enabling uniform density control and reducing defects by heating and pressing the composition onto a current collector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional rolling process is used to compress electrode, then electrode density is increased, but uniformity of density control deteriorates due to shear force causing wrinkles
Solution Approach 1:
Instead of compressing the electrode from both sides simultaneously (conventional rolling), this invention inverts the approach by supporting the electrode on one side (first roller) and applying compression only from the other side (second roller). This unilateral compression eliminates the shear forces that cause wrinkles while still achieving the desired density increase.
Solution Approach 2:
The invention applies compression locally at specific positions rather than uniformly across the entire electrode width. By positioning the second roller to compress only the coated portion of the electrode while the first roller supports the rest, it achieves density control without generating harmful shear forces that cause wrinkles.
2Ease of manufacture
If direct lamination method is used in dry process, then manufacturing simplicity is improved, but control over gap and pressure during lamination deteriorates
Solution Approach 1:
The invention transforms the static gap control problem into a dynamic solution by using rollers of different diameters. The rotational speed difference between the first and second rollers automatically controls the gap and pressure during lamination, providing precise control without complex adjustment mechanisms.
Solution Approach 2:
The invention changes the physical parameter of roller diameter to achieve precise control over lamination gap and pressure. By using rollers with different diameters, the system can control the compression force and gap dynamically during the lamination process, maintaining both simplicity and precision.
3Productivity
If conventional rolling compresses electrode from both sides, then compression efficiency is improved, but defect rate increases due to shear force in width direction
Solution Approach 1:
The invention inverts the conventional two-sided compression approach by implementing unilateral compression. The first roller serves as a support roller while the second roller applies compression force, eliminating the opposing forces that generate shear stress and wrinkles, thus reducing defects while maintaining compression efficiency.
Solution Approach 2:
The invention segments the compression function into two distinct roles: the first roller provides support and the second roller provides compression. This segmentation of functions allows for controlled compression without the harmful interactions that occur when both rollers attempt to compress simultaneously from opposite directions.
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 apparatus and method achieve uniform electrode density and reduced defect rates, improving process efficiency and enabling high-quality electrode production.
Implementation Method 1
increasing the electrode density by compressing the electrode through compressive force generated between the rotating rollers
Implementation Method 2
heating and pressing the composition onto a current collector
Implementation Method 3
forces are generated in various directions; among these, shear force in the width direction
Implementation Method 4
the dry electrode sheet is laminated on a current collector supplied from the outside
Data Source
AI summary
The present disclosure relates to an apparatus for manufacturing an electrode and a method for manufacturing an electrode. An electrode manufacturing apparatus according to one embodiment comprises: a dry electrode composition supply portion; a laminating portion; a first roller and a second roller configured to process the dry electrode composition supplied from the dry electrode composition supply portion into a dry electrode sheet while transferring it to the laminating portion; wherein the first roller and the second roller have different diameters from each other, and wherein, in the laminating portion, the dry electrode sheet can be laminated on a current collector supplied from the outside.