Electrode Design for Accurate Edge Detection and Adhesion
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Solution Overview
Problem
The adhesion between electrodes in batteries is not sufficiently secured due to material differences, leading to issues in detecting the edge of the active material layer accurately, which affects battery performance and manufacturing accuracy, and the combination of conductive layers and pressing techniques causes bending of the electrode plate during manufacturing.
Innovation Solution
An electrode design with a conductive layer on the electrode plate and an active material layer formed continuously, including an uncoated region where the electrode plate is exposed, allows for accurate optical detection of the active material layer edge and prevents bending by ensuring the conductive layer is not exposed beyond the active material layer, thereby improving adhesion and manufacturing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conductive layer is formed on the electrode plate to improve adhesion, then adhesion strength increases, but the conductive layer may be exposed beyond the active material layer causing detection errors
Solution Approach 1:
The patent applies different properties to different regions: the conductive layer is formed only in the active material formation region, not in the uncoated region. This local differentiation ensures the conductive layer provides adhesion where needed while avoiding exposure that would cause detection errors at the edges
Solution Approach 2:
The conductive layer is formed in advance on the electrode plate before the active material layer is applied. This preliminary action ensures proper adhesion is established beforehand, and the subsequent formation of the active material layer naturally covers the conductive layer boundary, preventing exposure issues
2Strength
If pressing techniques are used to improve adhesion between layers, then adhesion improves, but the electrode plate bends during manufacturing
Solution Approach 1:
The patent removes the need for pressing techniques by ensuring the active material layer completely covers the conductive layer. This extraction of the pressing step eliminates the bending problem while maintaining adhesion through proper layer coverage and formation
Solution Approach 2:
The conductive layer is formed preliminarily on the electrode plate before active material application. This preliminary formation, combined with ensuring the active material layer covers the entire conductive layer, creates sufficient adhesion without requiring subsequent pressing operations that would cause bending
3Strength
If the conductive layer is formed to completely cover the electrode plate, then adhesion is maximized, but optical detection of the active material layer edge becomes inaccurate
Solution Approach 1:
The conductive layer is selectively formed only in the active material formation region, creating a local quality difference. This ensures the conductive layer provides adhesion where the active material is present while leaving the uncoated region free of conductive layer, enabling accurate optical detection of edges
Solution Approach 2:
The electrode plate is segmented into two functional regions: the active material formation region where the conductive layer is formed for adhesion, and the uncoated region where no conductive layer is formed to maintain optical detection accuracy. This segmentation resolves the contradiction between adhesion and detection
Data Source
AI summary
An electrode includes: an electrode plate; a conductive layer formed on the electrode plate; and an active material layer formed continuously on the electrode plate and on the conductive layer, and the electrode plate includes an uncoated region where a surface of the electrode plate is exposed.