Patterned Electrode Plate Flattening for Anti-Curl Battery Manufacturing
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Solution Overview
Problem
Secondary battery electrode plates often curl during manufacturing due to differences in elongation between coated and uncoated surfaces, leading to slip, vacuum errors, and misalignment during processing, which decreases productivity.
Innovation Solution
An electrode plate manufacturing apparatus and method that uses a polygon roller with convex curved portions to form a pattern on the substrate, reversing the curl and maintaining the electrode plate flat, thereby preventing slip and vacuum errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating layer is formed on one surface of the substrate, then the electrode plate achieves functional requirements for battery operation, but the electrode plate curls during manufacturing due to differential elongation between coated and uncoated surfaces
Solution Approach 1:
The patent applies preliminary anti-action by forming a pattern on the uncoated surface of the substrate before battery assembly. This pattern creates preliminary stress that counteracts the curling force generated by the coating layer, preventing the electrode plate from curling during subsequent manufacturing processes while maintaining the functional integrity of the coating layer.
Solution Approach 2:
The patent applies local quality by creating a patterned structure only on the uncoated surface of the substrate, rather than uniformly treating the entire surface. This localized modification allows the coated surface to maintain its functional properties while the patterned uncoated surface provides the necessary mechanical counterbalance to prevent curling.
2Productivity
If the electrode plate curls during processing, then manufacturing continues, but slip, vacuum errors, and misalignment occur which decrease productivity
Solution Approach 1:
The patent applies preliminary action by forming the pattern on the substrate surface before the electrode plates are stacked and processed. This advance preparation ensures that the anti-curling effect is already in place before processing begins, preventing slip, vacuum errors, and misalignment during subsequent manufacturing steps, thereby maintaining both productivity and processing stability.
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 curling of electrode plates, maintains their flatness, and enhances productivity by reducing slip and vacuum errors during processing and stacking.
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
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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.