Electrode Edge Form Control via Recessed Roller
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Solution Overview
Problem
Existing methods for producing electrodes, such as those for lithium ion secondary batteries, face challenges in precisely controlling the edge form of the electrode active material layer, particularly when using moisture powders or dry powders with suitable viscosity, which is crucial for achieving high precision in electrode production.
Innovation Solution
A method involving a long sheet-shaped electrode current collector with a coating film formed in the sheet longitudinal direction, where the edges of a forming roller come into contact with a coating film-non-formed part to adjust the edge form, and a backup roller is used to prevent breakage, with a rotational speed ratio between the rollers optimized to 0.98:1.02, utilizing a gas phase-controlled moisture powder with a high ratio of solid, liquid, and gas phases to ensure efficient edge control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If control members are used to control the form of both edges of the coating film, then the edge form is favorably controlled, but the manufacturing precision is insufficient for high precision electrode production
Solution Approach 1:
The invention changes the geometric parameters of the forming roller, specifically introducing a recessed portion with controlled depth and width. By adjusting the depth (0.1-10 mm) and width (1-50 mm) of the recessed portion, the roller can precisely control the edge form of the coating film without requiring complex control members, thereby achieving high manufacturing precision through simple parameter modification
Solution Approach 2:
The recessed portion is pre-formed on the forming roller surface before the coating process. This preliminary structural preparation allows the roller to automatically control the edge form of the coating film during the forming process without requiring additional control members or complex mechanisms, thus improving precision while maintaining device simplicity
2Reliability
If a forming roller with contact regions is used to control edge form, then coating film leakage is prevented, but the roller design becomes more complex
Solution Approach 1:
The forming roller is designed with local quality variation through the recessed portion structure. The roller surface has different geometric characteristics at different locations: the contact regions have higher curvature for edge control, while the central part has lower curvature for uniform compression. This local differentiation prevents coating film leakage without requiring a completely complex roller design
Solution Approach 2:
The forming roller surface is segmented into distinct functional zones: contact regions for edge control and a central part for overall compression. This segmentation allows each zone to perform its specific function effectively, preventing coating film leakage through the contact regions while maintaining simple overall roller structure
3Manufacturing precision
If rotational speed ratio between forming roller and backup roller is optimized to 0.98-1.02, then edge form control is improved, but the control system becomes more complex
Solution Approach 1:
The invention optimizes the rotational speed ratio parameter between the forming roller and backup roller to a specific range (0.98-1.02). By adjusting this single parameter, the system achieves improved edge form control and manufacturing precision without requiring complex control systems, as the speed ratio can be easily adjusted through motor control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively prevents coating film leakage and enables compression molding, resulting in an electrode active material layer with precisely controlled edges, enhancing the production of high-precision electrodes.
Implementation Method 1
bringing the coating film into contact with the central part of a recessed portion present between contact regions at a prescribed contact pressure
Implementation Method 2
the rotational speed ratio (A/B) is such that 0.98≤A/B≤1.02
Data Source
AI summary
Provided is a method for producing an electrode having an electrode active material layer in which the form of both edges is advantageously adjusted. A method for producing an electrode disclosed here is a method for producing an electrode which includes a long sheet-shaped electrode current collector of a positive electrode or a negative electrode; and a long sheet-shaped electrode active material layer formed on the electrode current collector. The method for producing an electrode includes the following steps: an electrode material preparation step for preparing an electrode material; a film formation step for forming a coating film in the sheet longitudinal direction on the electrode current collector using the electrode material; and a roller forming step for adjusting the form of both edge parts in the sheet longitudinal direction of the coating film using a forming roller.