Multi-Roll Electrode Calendering for Thin Battery Plate Thickness Control
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Solution Overview
Problem
Existing secondary battery manufacturing processes face challenges in achieving high precision, preventing material wrinkles and breakage, and controlling rolling thickness during the formation of electrode plates.
Innovation Solution
A secondary battery manufacturing apparatus is designed with a pair of main rolls and a pair of sub-rolls, where the main rolls rotate in opposite directions to the sub-rolls, applying controlled pressure to roll electrode plates, and includes a processor to sense thickness and temperature, adjusting rolling pressure and temperature accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single pair of press rolls is used to roll the electrode plate, then the device complexity is low, but the manufacturing precision and control over rolling thickness are insufficient
Solution Approach 1:
The press rolls are segmented into multiple pairs: a first pair of press rolls and a second pair of press rolls arranged in sequence. Each pair independently rolls the electrode plate, allowing staged compression and precise thickness control at different positions, thereby resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
The patent introduces a vertical stacking dimension by arranging press rolls in multiple pairs along the rolling direction. This multi-level configuration enables progressive thickness reduction with better control, transitioning from a single-plane rolling approach to a multi-dimensional staged rolling system.
2Manufacturing precision
If high rolling pressure is applied to achieve high density electrode plates, then the density increases, but material wrinkles and breakage occur
Solution Approach 1:
The first pair of press rolls performs preliminary rolling to pre-compress and stabilize the electrode plate structure before the second pair applies higher pressure. This preliminary action prevents material instability that would lead to wrinkles and breakage during subsequent high-pressure rolling, enabling high density without damage.
Solution Approach 2:
The patent employs dynamic, staged pressure application through multiple press roll pairs rather than static single-stage compression. Each pair applies pressure sequentially, allowing the material to adapt and densify progressively, achieving high density while avoiding the sudden stress that causes wrinkles and breakage.
3Manufacturing precision
If the electrode plate is rolled to reduce thickness, then the thickness deviation decreases, but the material may wrinkle or break
Solution Approach 1:
The rolling process is segmented into multiple stages with different press roll pairs handling different aspects of thickness control. The first pair establishes baseline uniformity while the second pair refines thickness precision, achieving controlled thickness reduction without the material instability that causes wrinkles and breakage.
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 achieves high-density composite electrode plates with controlled thickness and reduces wrinkling and breakage, ensuring precise manufacturing of thin electrode plates.
Implementation Method 1
a plurality of press rolls arranged to roll an electrode plate... configured to perform rolling by pressing the electrode plate
Implementation Method 2
one of the pair of main rolls may be configured to rotate in a first direction and the corresponding one of the pair of sub-rolls may be configured to rotate in a second direction different from the first direction
Data Source
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AI summary
Disclosed is a secondary battery manufacturing apparatus for manufacturing high density and/or thin electrode plates. The secondary battery manufacturing apparatus includes: a press roll for rolling an electrode plate. The press roll includes a pair of main rolls having a first diameter and a pair of sub-rolls having a second diameter less than or equal to the first diameter. A conveying unit conveys the electrode plate toward the press roll.