Dual Pressure Roll Electrode Calendering for Wrinkle Prevention
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Solution Overview
Problem
Existing electrode manufacturing devices struggle to prevent the generation of wrinkles and folds on the non-coating part of electrodes, which can compromise the integrity and performance of battery modules.
Innovation Solution
The electrode manufacturing device employs a first pressure roll and a second pressure roll with a controlled radius difference, where the first pressure roll applies pressure to the non-coating part and the second pressure roll applies pressure to the coating part, with a connection part penetrating through their centers, ensuring the radius difference matches the step difference between the coating and non-coating parts, and includes sliding parts to ensure uniform pressure application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single pressure roll is used to apply pressure to the electrode, then the device structure is simple, but wrinkles and folds cannot be effectively prevented on the non-coating part
Solution Approach 1:
The pressure application device is segmented into two separate pressure rolls: a first pressure roll that applies pressure to the non-coating part and a second pressure roll that applies pressure to the coating part. This segmentation allows each pressure roll to be independently optimized for its specific function, effectively preventing wrinkles and folds on the non-coating part while maintaining pressure on the coating part.
Solution Approach 2:
Different pressure rolls are designed with different local qualities - the first pressure roll has a surface configured to match the non-coating part geometry, while the second pressure roll is configured for the coating part. This local quality differentiation enables each pressure roll to optimally address the specific surface characteristics of its target area, preventing defects where needed without affecting other areas.
2Manufacturing precision
If pressure is applied uniformly across the entire electrode, then the manufacturing process is simple, but the step difference between coating part and non-coating part causes wrinkles and folds
Solution Approach 1:
The pressure application mechanism employs local quality by configuring the first pressure roll with a surface that corresponds to the non-coating part geometry. This localized configuration allows the pressure to be adapted to the specific surface characteristics of different electrode regions, eliminating wrinkles and folds caused by step differences while maintaining manufacturing precision.
Solution Approach 2:
The system changes the pressure application parameters by using two pressure rolls with different surface configurations and pressure characteristics. The first pressure roll is specifically parameterized for the non-coating part, while the second is parameterized for the coating part, allowing precise control over pressure distribution to prevent surface defects.
3Manufacturing precision
If the radius difference between pressure rolls is not controlled, then the device is easier to manufacture, but wrinkles and folds occur on the non-coating part
Solution Approach 1:
The invention controls the radius difference between the first and second pressure rolls as a critical parameter. By setting the radius difference to be equal to or smaller than the step difference between the coating part and non-coating part, the system achieves optimal pressure distribution that prevents wrinkles and folds while remaining manufacturable through precise radius control.
Data Source
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AI summary
An electrode manufacturing device according to one embodiment of the present embodiment is an electrode manufacturing device that applies pressure to an electrode containing a coating part and a non-coating part, the electrode manufacturing device comprising: a first pressure roll that applies pressure to the non-coating part; a second pressure roll that applies pressure to the coating part; and a connection part that penetrates through the center of the first pressure roll and the center of the second pressure roll, respectively, wherein a difference between a radius of the first pressure roll and a radius of the second pressure roll is equal to or smaller than a step difference between the coating part and the non-coating part.