Electrode Plate Cutting with Pre-Incision Burr Reduction

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Solution Overview

Problem

Existing methods for manufacturing electrode plates using die roll cutters result in burrs and electrode active material layer dropout, leading to decreased battery quality.

Innovation Solution

A cutting device and method that uses two cutting blades to form incisions in the active material layers before cutting, reducing friction and burr formation by minimizing the amount of blade advancement into the continuous body.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a die roll cutter is used to punch the electrode material, then the electrode plate can be manufactured, but burrs and electrode active material layer dropout occur leading to decreased battery quality

Engineering Contradiction:

Improvecut surface qualityVSAvoidburr formation and material dropout

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The cutting process is divided into two separate stages: first forming an incision in the active material layer, then completing the cut through the current collector plate. This segmentation allows each stage to be optimized independently, preventing burr formation by separating the cutting actions that previously occurred in a single punch operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The incision is formed in the active material layer before the final cutting action. This preliminary action creates a pre-defined path that guides the subsequent cutting blade, ensuring clean separation without burrs or material dropout. The incision step prepares the material structure in advance to receive the final cut cleanly.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If the cutting blade advances deeply into the continuous body to cut through all layers, then complete separation is achieved, but friction increases causing burrs and material damage

Engineering Contradiction:

Improvecut completenessVSAvoidfriction-induced burrs

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The cutting action is segmented into two phases: forming an incision that penetrates the active material layer, and then completing the cut through the current collector plate. This reduces the depth of blade advancement in each phase, minimizing friction and burr formation while still achieving complete separation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The incision acts as an intermediary structure that facilitates the final cutting action. By pre-forming this incision, the subsequent cutting blade follows a prepared path with reduced resistance, minimizing friction-induced burrs and material damage while ensuring complete cut-through.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12583144B2Cutting device and cutting method

Publication Date: 2026.03.24 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A cutting device for cutting a continuous body of an electrode plate, the electrode plate including a current collector plate, a first active material layer, and a second active material layer, the cutting device including: a first process unit that causes a first cutting blade to form an incision in the first active material layer; and a second process unit that causes a second cutting blade to cut the continuous body.