Lithium-Ion Battery Electrode Porosity Control via Pre-Cutting
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Solution Overview
Problem
Existing methods for producing electrodes for energy storage cells, such as lithium ion batteries, often result in undesired deformations like folds and cracks due to force application during calendering, leading to quality losses and increased manufacturing complexity and costs.
Innovation Solution
A method that modifies the conventional process by producing single sheets with a lead region and coating them before adjusting porosity, using mechanical or thermal cutting methods, and applying pressure perpendicularly to avoid mechanical stress, allowing for higher compression and density without uncoated regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the carrier material is coated first and then compacted during calendering, then the porosity can be adjusted, but undesired deformations such as folds and cracks occur in the uncoated regions
Solution Approach 1:
The patent applies preliminary action by cutting the carrier material into single sheets before coating. This preliminary cutting action removes the uncoated regions that would later cause deformations during calendering, preventing the harmful effect before it occurs. The single sheets are then coated and compacted without the problematic uncoated edges.
Solution Approach 2:
The patent applies segmentation by dividing the continuous carrier material web into individual single sheets before coating. This segmentation creates discrete units with defined edges, eliminating the uncoated regional issues that arise in continuous web processing during subsequent coating and calendering operations.
2Quantity of substance
If force is applied during calendering to adjust porosity, then the electrode density is improved, but quality losses occur due to crack formation
Solution Approach 1:
The patent applies preliminary action by pre-cutting the carrier material into single sheets before coating and calendering. This eliminates uncoated edges that would otherwise concentrate stress during force application, preventing crack formation while allowing effective porosity adjustment and density improvement during calendering.
3Object-affected harmful factors
If heating is applied to uncoated regions to counteract deformations, then fold formation is reduced, but manufacturing complexity and costs increase
Solution Approach 1:
The patent applies the taking out principle by removing the uncoated regions through preliminary cutting into single sheets. This extraction of the problematic uncoated edges eliminates the need for additional heating equipment and processes, directly reducing manufacturing complexity and costs while preventing fold formation.
Solution Approach 2:
The patent applies preliminary action by pre-cutting the carrier material into single sheets before coating. This preliminary action prevents fold formation at the source by eliminating uncoated regions, making subsequent heating measures unnecessary and thereby reducing manufacturing complexity.
4Shape
If laser cutting is used on deformed films, then contour cutting can be performed, but focusing becomes difficult due to pre-existing deformations
Solution Approach 1:
The patent applies preliminary action by cutting the carrier material into single sheets before coating and calendering. This ensures that the film surface remains flat and undeformed throughout subsequent processing, providing an optimal substrate for laser contour cutting with proper focusing, thereby maintaining high manufacturing 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
This approach prevents deformations, enhances electrode density, and simplifies processing, leading to improved energy and power densities while reducing manufacturing complexity and costs.
Implementation Method 1
the electrode is compacted, particularly in order to adjust a porosity, for example by a calender process
Implementation Method 2
Film cutting by means of a laser may also be made more difficult since it is not possible to focus correctly
Data Source
AI summary
Please substitute the new Abstract submitted herewith for the original Abstract: A method for producing an electrode, especially for a lithium-ion battery, includes providing an uncoated carrier material, machining the carrier material to produce at least one single sheet, coating the single sheet, and adjusting the porosity of the electrode at the single sheet level.