Electrode Foil Coating Layout for Wrinkle-Free Calendaring
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Solution Overview
Problem
The manufacturing of electrode foils for energy storage devices faces challenges in avoiding wrinkles, which are caused by uneven stretching during the calendaring process, leading to substrate foils that are not usable for further manufacturing steps.
Innovation Solution
A method involving continuous coating of a substrate foil with a coating material in central electrode coating portions and peripheral coating portions, where the thickness and width of the peripheral coating portions are designed to match or exceed those of the central electrode coating portion, allowing for uniform pressure application and reduction of wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressure is applied to the coated substrate foil during calendaring, then the thickness distribution is adjusted, but wrinkles are caused due to uneven stretching of the substrate foil
Solution Approach 1:
The invention applies local quality by coating only specific portions of the substrate foil (central electrode coating portion and peripheral coating portions) rather than the entire surface. This creates localized coated areas with different mechanical properties, allowing the coated portions to be stretched uniformly during calendaring while the uncoated portions remain relatively unchanged, thus preventing wrinkles while achieving desired thickness distribution.
Solution Approach 2:
The invention segments the coating application into distinct regions: a central electrode coating portion and peripheral coating portions. This segmentation allows different areas of the substrate foil to experience different degrees of stretching during calendaring, with the coated portions being uniformly stretched and the uncoated portions serving as reference areas, thereby eliminating the harmful uneven stretching that causes wrinkles.
2Reliability
If additional heating devices are used to eliminate wrinkles, then the wrinkle elimination effect is improved, but the device complexity increases
Solution Approach 1:
The invention employs self-service by using the coating material itself and the calendaring process to achieve wrinkle prevention. The coated portions of the substrate foil are stretched uniformly during calendaring, which inherently prevents wrinkles from forming. This eliminates the need for additional heating devices or complex wrinkle elimination equipment, as the coating-calendaring system itself provides the wrinkle-free surface.
Data Source
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AI summary
The invention relates to a method of manufacturing an electrode foil. The method comprises conveying a substrate foil in a conveying direction, and continuous coating the substrate foil with a coating material in at least one central electrode coating portion and a first peripheral coating portion of the substrate foil, wherein a thickness of the coated first peripheral coating portion is similar to or larger than a thickness of the coated central electrode coating portion, and wherein a width of the central electrode coating portion is larger than a width of the first peripheral coating portion. The method further comprises applying a pressure to the central electrode coating portion and the first peripheral coating portion, and removing the first peripheral coating portion at least partially.