Irregular Electrode Coating Pattern for Material Waste Reduction
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Solution Overview
Problem
Existing methods for manufacturing irregular-shaped electrodes for secondary batteries result in material waste and complex processes, such as cutting rectangular electrodes to form L-shapes or requiring separate processes for different-sized electrodes.
Innovation Solution
A method involving a collector preparation, coating with electrode active material in specific patterns, and cutting to form electrodes with L-shapes by using first to fifth coating areas with varying lengths and connections, minimizing waste and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If rectangular electrodes are cut to form L-shaped electrodes, then irregular-shaped electrodes can be manufactured, but electrode active material is discarded without being used causing material waste
Solution Approach 1:
The patent applies preliminary action by forming coating areas with specific patterns (first to fifth coating areas with varying lengths L1-L5) on the collector before cutting. The coating pattern is pre-designed to match the final irregular electrode shape, so that only the necessary areas are coated with active material. This prevents material waste by ensuring that uncoated areas correspond exactly to the portions that will be removed during cutting to create the L-shape.
Solution Approach 2:
The patent applies local quality by creating different coating areas (first to fifth coating areas) with different lengths and properties on different portions of the collector. Each coating area is selectively coated based on its position and required function in the final electrode shape. This allows precise control of material application, coating only where needed for the irregular shape while leaving other areas uncoated to be removed during cutting.
2Shape
If two kinds of rectangular electrodes are manufactured and attached to each other to form L-shaped electrode, then irregular-shaped electrodes can be manufactured, but the manufacturing process becomes complicated
Solution Approach 1:
The patent applies merging by combining multiple coating operations into a single integrated process. Instead of manufacturing separate rectangular electrodes and assembling them, the method forms first to fifth coating areas on a single collector in one coating process, then cuts the entire structure in one operation to produce the L-shaped electrode. This unifies multiple steps into a streamlined process, reducing complexity while achieving the same geometric result.
Solution Approach 2:
The patent applies segmentation by dividing the coating process into distinct coating areas (first to fifth coating areas) with different lengths (L1-L5) that correspond to different segments of the final L-shaped electrode. Each coating area is formed in a controlled manner and then all segments are integrated through a single cutting operation, simplifying the overall process compared to assembling pre-manufactured components.
3Adaptability or versatility
If separate processes are used to manufacture different-sized rectangular electrodes, then various electrode sizes can be produced, but the manufacturing process becomes complicated
Solution Approach 1:
The patent applies universality by designing a single coating process that can produce multiple coating areas with different lengths (L1, L2, L3, L4, L5) on the same collector. This multi-functional coating approach allows the production of electrodes with varying sizes and configurations from one process setup, eliminating the need for separate manufacturing lines for different electrode dimensions while maintaining flexibility in producing various sizes.
Data Source
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AI summary
Disclosed is a method for manufacturing an electrode. According to the present invention, the electrode having the irregular shape through the simple process while minimizing the amount of wasted electrode active material may be manufactured. To achieve the above object, according to the present invention, first to third coating areas are formed to be spaced apart from each other on a collector, a plurality of fourth coating areas are formed between the first coating area and the second coating area, and a plurality of fifth coating areas are formed between the second coating area and the third coating area, wherein the plurality of fourth coating areas and the plurality of fifth coating areas are dislocated from each other when viewed from one side in a width direction of the collector.