Electrode Forming Belt Transfer for Uniform Mass Distribution
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Solution Overview
Problem
Existing methods for manufacturing electrodes, particularly for lithium-ion batteries, face challenges in achieving uniform mass distribution and productivity due to issues like solvent retention, non-uniform density distribution, and pulsation during the formation process, especially in all-solid state batteries.
Innovation Solution
A method involving a pair of transport belts where the electrode material is introduced between the belts, pressed, and then transferred to a deposition belt with intersecting transport directions, ensuring uniform mass distribution and productivity by controlling pressure and belt speeds, and using inclined belts to manage material flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a coating liquid containing electrode material and solvent is used to form an electrode, then the electrode can be formed with continuous material supply, but solvent remains in the electrode reducing battery performance
Solution Approach 1:
The patent extracts and removes the solvent from the electrode material through drying processes after coating, separating the useful electrode material from the harmful solvent that reduces battery performance
Solution Approach 2:
The patent applies preliminary drying treatment to the coated electrode material before battery assembly to remove solvent in advance, preventing performance degradation that would occur if solvent remained in the final product
2Manufacturing precision
If pressing rolls are used to compact powder onto substrate, then the electrode material is densified, but non-uniform density distribution occurs in the electrode
Solution Approach 1:
The patent transitions from static pressing rolls to dynamic belt conveyors that move continuously, allowing the electrode material to be compacted and transported in a continuous flow, improving both uniformity and productivity
Solution Approach 2:
The patent changes the pressing mechanism from point-contact rolls to surface-contact belts, adding a dimensional aspect that distributes pressure more uniformly across the electrode material width
3Reliability
If airflow control plate is used to suppress air inclusion during pressing, then air is reduced in longitudinal direction, but airflow generates uneven density distribution in width direction
Solution Approach 1:
The patent removes the airflow control plate that caused uneven density distribution in the width direction, eliminating the source of the problem while maintaining air inclusion control through alternative means
Solution Approach 2:
The patent applies gentle, distributed pressure through wide belts rather than concentrated airflow, using partial action across the entire width to achieve uniform compaction without creating localized density variations
4Manufacturing precision
If multiple components are added to improve electrode formability, then the electrode quality is enhanced, but productivity decreases
Solution Approach 1:
The patent combines multiple functions (coating, compaction, drying, and transport) into a single integrated belt conveyor system, eliminating the need for separate components and processes that would reduce productivity
Solution Approach 2:
The belt conveyor system performs multiple functions simultaneously - it transports material, applies compaction pressure, and facilitates drying - making the system versatile and eliminating the need for multiple specialized components
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 method maintains in-plane uniformity of mass distribution and enhances productivity by reducing solvent retention and density variations, leading to improved battery performance.
Implementation Method 1
a second step of belt-transporting and pressurizing the introduced electrode material with the pair of transport belts
Implementation Method 2
a first step of dropping an electrode material containing an electrode active material into a gap between a pair of transport belts
Data Source
AI summary
A method of manufacturing a formed body for an electrode includes a first step of dropping an electrode material containing an electrode active material into a gap between a pair of transport belts and introducing the electrode material between transport surfaces of the pair of transport belts; a second step of belt-transporting and pressurizing the introduced electrode material with the pair of transport belts; and a third step of transferring the electrode material after the belt transporting and the pressurization, on a deposition belt, in which a transport direction in a transport, passage through which the electrode material is transported, of the deposition belt intersects a transport direction in a transport passage, through which the electrode material is transported, of the pair of transport belts.