Electrode Current Collector Grooving for Ordered Active Layer Edges
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Solution Overview
Problem
The intermittent formation of the active material layer on the electrode current collector results in a disordered shape at the end portion, which can reduce battery performance.
Innovation Solution
The method involves forming a groove portion in the active material layer, peeling off a part of the layer to improve peel strength in one region while reducing it in another, and applying vibration to facilitate easy peeling, thereby maintaining a less disordered end portion shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the active material layer is formed intermittently on the electrode current collector, then the exposed region can function as a reserve space for cutting and welding, but the end portion shape of the active material layer becomes disordered
Solution Approach 1:
The active material layer is divided into a first portion (on adhesive layer) and a second portion (on metal foil). The groove portion is formed in each portion separately, with different depths in different regions, enabling selective peeling of the second portion while maintaining the first portion's ordered shape.
Solution Approach 2:
The groove portion has different depths in different regions: a first depth in the first portion and a second depth in the second portion. This local variation in groove depth creates different peel strengths in different regions, allowing the second portion to be easily peeled while the first portion remains firmly attached.
2Strength
If the groove portion is formed in the active material layer, then the peel strength can be controlled in different regions, but the manufacturing process becomes more complex
Solution Approach 1:
The groove portion is formed in advance during the active material layer formation process, before the peeling operation. This preliminary grooving enables subsequent easy peeling of the second portion by simply applying vibration, eliminating the need for complex post-processing equipment.
Solution Approach 2:
Vibration is applied to the active material layer to facilitate peeling of the second portion. The vibration, combined with the pre-formed groove portions, enables easy separation of the second portion from the metal foil without requiring complex peeling mechanisms.
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 approach enhances the peel strength of the active material layer, improves the shape orderliness of the end portion, and increases energy density by ensuring a steep end surface, thus improving battery performance.
Implementation Method 1
Due to the formation of the groove portion, the first portion is firmly adhered to the metal foil. That is, the peel strength of the first portion can be improved.
Implementation Method 2
applying vibration to facilitate easy peeling
Data Source
AI summary
An electrode is manufactured by forming an active material layer on a surface of an electrode current collector, forming a groove portion on a surface of the active material layer, and peeling off a part of the active material layer. An electrode current collector includes a metal foil and an adhesive layer. The metal foil includes a first region and a second region. The adhesive layer covers the first region. In the second region, the metal foil is exposed. The active material layer includes a first portion that covers the adhesive layer and a second portion that covers the second region. The groove portion is formed in each of the first portion and the second portion. The second portion is peeled off.