Electrode Layer Pressing Sequence to Prevent Collector Foil Damage
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Solution Overview
Problem
Conventional methods of manufacturing energy storage apparatuses result in damage to current collector foils due to high pressing pressures applied to active materials that are not easily crushed, leading to pinholes and strains in the foil.
Innovation Solution
A method of manufacturing energy storage apparatuses where a first active material layer, which is more easily crushed than a second layer, is located on the current collector foil and pressed at a pressure equal to or higher than the pressure applied to the second layer, thereby reducing strain and preventing damage to the foil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressing pressure is applied to active material that is not easily crushed, then the active material is properly compacted, but the current collector foil is damaged with pinholes and strains
Solution Approach 1:
The patent applies preliminary action by first pressing the easily crushed active material at high pressure to achieve proper compaction, then subsequently pressing the not easily crushed active material at lower pressure. This sequence ensures the current collector foil is already supported by the first layer before the second pressing operation, preventing pinhole formation while maintaining compaction quality.
Solution Approach 2:
The patent segments the pressing process into two distinct stages: first pressing the easily crushed active material, then pressing the not easily crushed active material. This segmentation allows each material type to be pressed at its optimal pressure without causing damage to the current collector foil, resolving the contradiction between compaction quality and foil integrity.
2Reliability
If pressing pressure is increased to ensure proper adhesion of active material, then adhesion quality improves, but the current collector foil develops pinholes
Solution Approach 1:
The easily crushed active material is pressed first at high pressure to establish proper adhesion to the current collector foil. This preliminary adhesion layer then supports the subsequent pressing of the not easily crushed active material, ensuring continued good adhesion without requiring high pressure that would cause pinholes.
Solution Approach 2:
The first easily crushed active material layer acts as a cushioning layer between the pressing mechanism and the current collector foil during the second pressing operation. This cushioning effect distributes the pressing pressure evenly, maintaining adhesion quality while preventing pinhole formation in the foil.
3Stability of the object's composition
If high pressing pressure is used for active material layers, then density and stability improve, but strain accumulates in the current collector foil
Solution Approach 1:
The pressing operation is segmented into two sequential steps with different pressure levels. The first step uses high pressure to achieve proper density and stability of the easily crushed active material. The second step uses lower pressure for the not easily crushed material, preventing strain accumulation in the current collector foil while maintaining overall structural integrity.
Solution Approach 2:
The first active material layer is pressed at high pressure beforehand to achieve proper density and stability. This creates a stable foundation that reduces the need for high pressure in subsequent pressing operations, thereby protecting the current collector foil from excessive strain while maintaining the required material 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
This approach minimizes damage to the current collector foil by using an easily crushable layer to absorb pressing forces, preventing pinholes and ensuring stable adhesion of the active material layers.
Implementation Method 1
the first active material layer, which is more easily crushed than the second active material layer, is located on the current collector foil, and is pressed at a pressure equal to the pressure at which the second active material layer is pressed
Data Source
AI summary
A method of manufacturing an energy storage apparatus includes locating a first active material layer of a positive electrode active material layer and a negative electrode active material layer on a current collector foil and pressing the first active material layer, and locating a second active material layer of the positive electrode active material layer and the negative electrode active material layer on the current collector foil and pressing the second active material layer together with the first active material layer. In the locating and pressing the first active material layer the first active material layer, which is more easily crushed than the second active material layer, is located on the current collector foil, and is pressed at a pressure equal to the pressure at which the second active material layer is pressed, or at a pressure higher than the pressure at which the second active material layer is pressed.