Asymmetric Electrode Plate Coating for Cold-Press Shear Relief
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Solution Overview
Problem
Existing electrode plates face challenges with structural strength and conductive performance due to excessive shear force during cold-pressing, particularly at the junction between the coated and blank foil sections.
Innovation Solution
The electrode plate design includes a current collector with a support layer and conductive layers, divided into a blank foil section and a coated section. The active material layers are strategically positioned on the conductive layers, ensuring that only one active material layer is present in the edge regions, reducing the thickness and alleviating shear force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the active material layer is coated on both sides of the edge region of the coated section, then the capacity and energy density of the electrode plate are improved, but the shear force during cold-pressing increases and structural strength deteriorates
Solution Approach 1:
The patent applies different coating configurations to different regions of the current collector. Specifically, the edge regions adjacent to the blank foil section have only one active material layer coated on one side, while the central coated section has active material layers on both sides. This local differentiation reduces shear force at vulnerable edge regions while maintaining high capacity in the central region.
2Quantity of substance
If the active material layer is coated on both sides of the edge region, then the energy density is improved, but the conductive performance deteriorates due to impaired structural strength
Solution Approach 1:
The patent implements asymmetric coating where edge regions have single-sided active material layers and central regions have double-sided coating. This ensures structural integrity and conductive performance at edge regions while maximizing energy density in the central coated section.
3Strength
If the thickness of the electrode plate at the edge region is reduced, then the shear force during cold-pressing is reduced and structural strength is improved, but the capacity and energy density deteriorate
Solution Approach 1:
The patent creates a thickness gradient across the electrode plate by coating only one side at edge regions (reducing thickness and shear force) while coating both sides at the central region (increasing capacity). This spatial variation optimizes both structural strength and capacity.
Solution Approach 2:
The current collector is functionally segmented into edge regions with single-sided coating and central regions with double-sided coating. This segmentation allows different structural configurations in different zones to optimize for their respective functions: edge regions for structural stability and central regions for maximum capacity.
Data Source
AI summary
A current collector includes a support layer and a first conductive layer and a second conductive layer that are disposed on two sides of the support layer in a thickness direction of the current collector. The current collector is divided into a first blank foil section and a coated section disposed in sequence in a second direction. A first active material layer is located on the coated section and disposed on a surface of the first conductive layer, the surface being oriented away from the support layer. A second active material layer is located on the coated section and disposed on a surface of the second conductive layer, the surface being oriented away from the support layer. Along the thickness direction of the current collector, a part of a projection of the first active material layer does not coincide with a projection of the second active material layer.