Electrode Forming with Segmented Material Supply for Uniform Sheet Mass
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Solution Overview
Problem
Existing methods for manufacturing electrode sheets face challenges in achieving uniform mass distribution, particularly with larger sheet widths, where the accuracy of pressing rolls or powder supply control is insufficient, leading to variations in density distribution.
Innovation Solution
A method involving the formation of at least two projecting portions of electrode material on a support, with specific height and distance relationships, and using movement regulating members to ensure uniform distribution, allows for improved uniformity by increasing fluidity and spreading of the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a fixed quantity feeder is used to supply electrode material to pressing rolls, then the supply amount can be controlled, but the mass distribution uniformity deteriorates due to pressing roll accuracy limitations
Solution Approach 1:
The electrode material supply is divided into multiple projecting portions (at least two) that are supplied separately onto the support. Each projecting portion is formed independently, allowing for better control of mass distribution across the width direction. This segmentation approach overcomes the limitation of using a single fixed quantity feeder with pressing rolls.
Solution Approach 2:
The electrode material is supplied in advance to form projecting portions with specific height relationships (where the height at the minimum point between neighboring projecting portions satisfies 0 ≤ L/Hmax < 0.5) before the leveling step. This preliminary formation of projecting portions ensures that the material is positioned and distributed appropriately before final leveling, improving mass distribution uniformity.
2Productivity
If the sheet width is increased, then the productivity is improved, but the mass distribution uniformity deteriorates due to difficulty in maintaining roll gap uniformity
Solution Approach 1:
Instead of relying on a single wide pressing roll gap that becomes difficult to maintain uniformly, the method segments the material supply into multiple narrower projecting portions across the width direction. This allows each portion to be formed with better control, maintaining mass distribution uniformity even as the overall sheet width increases for higher productivity.
Solution Approach 2:
The invention introduces a height dimension by forming projecting portions with specific height relationships (L/Hmax ratio control) before leveling. This dimensional approach allows the material to self-adjust and spread more uniformly across the width direction, overcoming the limitations of width-only control through pressing roll gap management.
3Quantity of substance
If powder supply from a single port is controlled by traveling wave, then the supply can be adjusted, but the mass distribution uniformity in width direction remains insufficient
Solution Approach 1:
The single powder supply port is replaced with multiple supply ports (at least two) that supply electrode material to form separate projecting portions side by side in the width direction. This segmentation allows independent control and distribution of material across different width positions, significantly improving mass distribution uniformity compared to a single port approach.
Solution Approach 2:
Each projecting portion is formed with specific local height characteristics (where the height at the minimum point between neighboring projecting portions satisfies 0 ≤ L/Hmax < 0.5). This local quality control ensures that each region of the electrode material has appropriate mass distribution, achieving overall uniformity across the width direction.
Data Source
AI summary
The present disclosure provides a method of manufacturing a formed body for an electrode including: a step of preparing an electrode material containing an electrode active material; a step of forming at least two projecting portions containing the electrode material and placed side by side on a support in a width direction of the support by supplying the electrode material onto the support; and a step of leveling the projecting portions on the support.