Dry Film Electrode Lamination Without Recompression Damage
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Solution Overview
Problem
The manufacturing of electrodes with dry film layers for batteries faces challenges due to low density, which affects energy and power density, and risks of wrinkling or cracking during recompression, especially in motor vehicle batteries.
Innovation Solution
A method and device that use rollers to form and compress dry film layers on a substrate with controlled line loads and circumferential speeds to achieve target densities and thicknesses, eliminating the need for additional recompression and minimizing damage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the dry film is recompressed during lamination to increase density, then energy and power density are improved, but the risk of wrinkling and cracking increases
Solution Approach 1:
The dry film is pre-compressed in a first compression device before lamination to achieve the desired density. This preliminary compression prevents the need for high-compression forces during lamination, thereby avoiding wrinkling and cracking while still achieving the required energy and power density.
Solution Approach 2:
The compression process is divided into two separate stages: first compression (before lamination) and lamination compression. This segmentation allows the dry film to be prepared in advance under controlled conditions, reducing mechanical stress during the lamination process and preventing defects.
2Quantity of substance
If high compression force is applied during lamination to achieve target density, then energy density is improved, but mechanical stress and damage risk increase
Solution Approach 1:
The dry film is pre-compressed to the target density before lamination, eliminating the need for high compression forces during the lamination process. This preliminary action ensures that the final product achieves the required density without subjecting the substrate to excessive mechanical stress.
3Quantity of substance
If additional recompression is performed to increase energy density, then power density is improved, but process complexity increases
Solution Approach 1:
The compression and lamination processes are merged into a coordinated sequence where pre-compression is performed immediately before lamination. This integration allows the dry film to be compressed and laminated in a continuous process flow, achieving the desired density without requiring separate, complex recompression steps after lamination.
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 method ensures reliable bonding of dry film layers to substrates with reduced mechanical stress, achieving suitable densities and thicknesses for battery applications without additional compression, thus enhancing energy and power density while preventing wrinkling or cracking.
Implementation Method 1
By using these rollers, pressure and/or shear forces are introduced into the dry film material so that the dry film forms
Implementation Method 2
By using these rollers, pressure and/or shear forces are introduced into the dry film material so that the dry film forms
Implementation Method 3
The dry film is conveyed on one of the rollers into another gap. In so doing, a substrate is additionally fed through this additional gap so that the dry film is laminated to the substrate
Data Source
AI summary
The disclosure relates to a method for manufacturing an electrode with a substrate and with a first dry film, wherein to form a first dry film, solvent-free dry film material is brought into a first nip formed between a first roller and a second roller. The first dry film formed in the first nip is conveyed roller-borne into a second nip formed between the second roller and a third roller and compressed there. For laminating, the compressed first dry film and the substrate are conveyed into a third nip formed between the third roller and a fourth roller, wherein the first dry film is conveyed roller-borne into the third nip. Moreover, the disclosure relates to a corresponding device for manufacturing the electrode.