Battery Electrode Plate Patterning to Prevent Curling in Pressing
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Solution Overview
Problem
In the manufacturing of half-cathode electrode plates for secondary batteries, the active material coating layer is stretched more than the uncoated portion during the press process, leading to curling of the electrode plate. This curling causes issues such as electrode plate slipping on conveyor belts, frequent vacuum errors during conveyance, and misalignment during stacking, resulting in decreased productivity.
Innovation Solution
An electrode plate manufacturing apparatus and method that includes a supply reel for providing a substrate with a coated surface and a pattern forming device using a polygon roller with convex curved portions to form a pattern on the substrate. The convex curved portions are arranged in a circumferential direction and have a continuous gradient, preventing curling by forming a reverse bending pattern on the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a press process is applied to the substrate during manufacturing, then the active material coating layer is stretched to form the desired shape, but the coating layer curls more than the uncoated portion causing electrode plate curling
Solution Approach 1:
The patent applies preliminary anti-action by forming a pattern on the uncoated portion of the substrate before the press process that creates a reverse bending effect. This pre-formed pattern counteracts the curling tendency of the coating layer during pressing, maintaining electrode plate flatness while still achieving the desired shape of the active material layer.
Solution Approach 2:
The patent applies local quality by creating a specific pattern only on the uncoated portion of the substrate, not the entire surface. This localized pattern formation allows differential treatment of different regions - the patterned uncoated portion compensates for curling while the coated portion maintains its intended shape, resolving the flatness issue without affecting the coating integrity.
2Productivity
If the electrode plate is conveyed on a conveyor belt, then production continues, but the curled electrode plate slips causing decreased productivity
Solution Approach 1:
The pattern formation on the uncoated portion creates a reverse bending effect that prevents curling before conveyance occurs. By addressing the flatness issue preliminarily, the electrode plate maintains stable contact with the conveyor belt throughout the production process, eliminating slipping problems and ensuring continuous reliable production.
3Extent of automation
If vacuum conveyance is used to transport the electrode plate, then automated handling is achieved, but vacuum errors occur frequently due to curling
Solution Approach 1:
The pattern formation process creates a reverse bending effect that maintains electrode plate flatness before vacuum conveyance. This preliminary action ensures the plate surface remains uniform and suitable for vacuum gripping, preventing air leakage and vacuum errors during automated handling while maintaining full automation benefits.
4Productivity
If stacking is performed to accumulate electrode plates, then production efficiency increases, but misalignment occurs due to curling
Solution Approach 1:
The pattern formation on the uncoated portion creates a reverse bending effect that maintains flatness before stacking. By preventing curling in advance, the electrode plates maintain consistent geometry during the stacking process, enabling high-speed accumulation without misalignment and preserving both productivity and precision.
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
The solution effectively prevents or reduces curling of the electrode plate, maintaining its flatness and preventing slipping on conveyor belts. This reduces vacuum errors during conveyance and improves alignment during stacking, thereby increasing productivity and safety in secondary battery manufacturing.
Implementation Method 1
forming a pattern on the substrate by passing the substrate between a polygon roller on which a plurality of convex curved portions are formed and a support roller while pressurizing the substrate
Data Source
AI summary
An electrode plate manufacturing apparatus for a secondary battery includes a supply reel configured to supply a substrate, the substrate having a first surface that is uncoated and a second surface that is at least partially coated, and a patterner adjacent to the supply reel, the patterner including a polygon roller and a support roller facing each other, the patterner being configured to pattern the substrate passing between the polygon roller and the support roller, and the polygon roller including convex curved portions that extend in an axial direction of the polygon roller and that are arranged in a circumferential direction of the polygon roller.