Selective Edge Material Deposition on Electrochemical Cell Foil Tabs

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Solution Overview

Problem

Current methods for forming edge materials on electrochemical cell components result in wasted materials as the entire surface of the edge portions is coated, leading to inefficiencies and increased costs.

Innovation Solution

A method involving a 3-dimensional printing process to selectively apply edge materials onto electrode tabs of a metallic foil substrate, using a profile machine to form tabs and notches, and multiple printing machines to apply layers of edge materials precisely, minimizing waste and optimizing material usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire surface of the edge portions is coated with edge materials, then the electrode tabs are protected from short circuits and strengthened, but edge materials are wasted

Engineering Contradiction:

Improveprotection from short circuitsVSAvoidedge materials waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent applies edge materials selectively only to the electrode tab regions rather than coating the entire edge portion surface. This localized application ensures that protection and strengthening are provided exactly where needed (on the tabs) while avoiding waste on areas that do not require these properties.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The coating process is segmented to target specific zones (electrode tabs) rather than applying a uniform coating across the entire edge portion. This segmentation allows precise material placement on the tabs while leaving other areas uncoated, reducing overall material consumption.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the entire surface of the edge portions is coated with edge materials, then the electrode tabs are protected from short circuits and strengthened, but material costs increase

Engineering Contradiction:

Improveprotection from short circuitsVSAvoidmaterial costs

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of applying edge materials to the entire edge portion surface (excessive action), the patent applies materials only to the necessary extent (partial action) - specifically on the electrode tabs where protection is required - thereby reducing material costs while maintaining functional reliability.

Inventive Principle:

Principle #16Partial or excessive action

3Loss of substance

If selective coating of electrode tabs is implemented, then edge materials are used efficiently, but manufacturing complexity increases

Engineering Contradiction:

Improveedge materials wasteVSAvoidcoating process complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical coating methods (which would require masking and complex positioning) with a 3D printing system. This substitution enables selective material deposition through digital control and precision positioning, achieving complex selective coating patterns without proportionally increasing mechanical system complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs a 3D printing process that uses digital parameters and computer-controlled positioning to achieve selective coating. By changing from mechanical parameter control to digital parameter control, the system achieves precise selective application with reduced overall process complexity.

Inventive Principle:

Principle #35Parameter changes

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 approach reduces material waste, allows for precise application of edge materials where needed, and lowers costs by ensuring only the necessary amount of edge materials is used, while providing additional strength and insulation to prevent short circuits.

Implementation Method 1

printing, via a 3-dimensional printing process, a layer of edge materials onto the plurality of electrode tabs

Methodology Applied

Scientific Effect3D Printing: 3D Printing

Data Source

PatentUS11715866B2Method of forming edge materials on electrochemical cell component

Publication Date: 2023.08.01 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method of forming edge materials on an electrochemical cell component having a metallic foil substrate including a conductive coating on top and bottom surfaces and first and second edge portions extending laterally outward beyond the conductive coating, includes pulling the metallic foil substrate from a roll, feeding the metallic foil substrate through a profile machine and forming notches within the first and second edge portions that extend inwardly from outermost edges of the first and second edge portions a distance less than a distance between the outermost edges and the conductive coating, and define a plurality of electrode tabs, feeding the strip of metallic foil substrate sequentially through a plurality of 3-dimensional printing machines and printing edge materials onto the electrode tabs and the first and second edge portions between the plurality of electrode tabs, and rolling the strip of metallic foil substrate onto a roll.