Electrode Plate Active Material Retention via Resin Infiltration
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Solution Overview
Problem
The existing methods for producing electrode plates in batteries face issues with active material removal during the manufacturing process, leading to decreased battery capacity and potential electrical short circuits, particularly due to weak bonding forces at the cutting surfaces of the active material filling area.
Innovation Solution
A method involving the infiltration of a liquid containing a resin and an organic solvent into the circumferential region of the active material filling area, which enhances the bonding forces between the active material particles and the conductive core body, preventing material removal and reducing the risk of electrical short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the circumferential part is covered with tape, then active material removal is restricted, but the production process becomes cumbersome and time-consuming
Solution Approach 1:
The patent extracts the harmful adhesive property from the tape and transfers it to the resin solution applied to the core body. The resin solution provides the necessary adhesive function without requiring external tape covering, thus eliminating the cumbersome tape application process while maintaining active material retention.
Solution Approach 2:
The resin solution serves multiple functions: it acts as a binder for active material particles, provides adhesive bonding to prevent removal, and eliminates the need for separate tape covering. This multi-functional approach simplifies the production process while maintaining reliability.
2Reliability
If a thermal-adhesive resin film is applied to the circumferential part, then active material removal is restricted, but the production process complexity increases
Solution Approach 1:
The patent removes the need for thermal-adhesive resin film application by incorporating adhesive resin directly into the coating applied to the core body. This eliminates the separate step of attaching thermal-adhesive films and the associated heating equipment requirements, reducing production process complexity while maintaining active material retention.
Solution Approach 2:
The resin solution acts as an intermediary substance that provides adhesive bonding between the core body and active material without requiring external adhesive films or thermal processing equipment. This simplifies the production system by eliminating complex thermal-adhesive film application machinery.
3Reliability
If resin solution is applied to the circumferential part, then active material removal is restricted, but drying time increases production cycle time
Solution Approach 1:
The patent modifies the parameters of the resin solution by selecting volatile organic solvents with appropriate evaporation rates and adjusting the resin concentration. This optimization allows the coating to achieve sufficient adhesive strength while reducing drying time, thus maintaining active material retention without excessive production cycle extension.
Solution Approach 2:
The patent applies the resin solution in a controlled manner during the electrode plate manufacturing process, timing the application and drying steps to coincide with other manufacturing operations. This periodic coordination minimizes the impact of drying time on overall production efficiency while ensuring active material retention.
4Quantity of substance
If the active material filling area is increased, then battery capacity increases, but active material removal risk increases at the circumferential part
Solution Approach 1:
The patent applies adhesive resin specifically to the circumferential region of the core body where active material removal is most likely to occur. This localized treatment provides enhanced retention at the vulnerable edges and surfaces while maintaining full active material filling in the central area, thus preserving battery capacity without compromising reliability.
Solution Approach 2:
The patent applies adhesive resin coating to the core body before filling with active material. This preliminary protective action prevents active material removal from the circumferential part during subsequent handling and battery assembly operations, allowing maximum active material filling without increased removal risk.
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 effectively restricts active material removal, maintains battery performance, and improves production efficiency by allowing for simultaneous processing of multiple electrode plates, reducing the need for complex equipment or cumbersome tape application methods.
Implementation Method 1
infiltrating a liquid containing a resin and an organic solvent into at least part of a circumference of the layer filled with the active material
Implementation Method 2
the liquid containing a resin and an organic solvent into at least part of a circumference of the layer filled with the active material
Data Source
AI summary
A production method for producing an electrode plate that can hold well the active material and producing a battery using the electrode plate. A production method for an electrode plate of a battery includes the steps of: forming at least one electrode plate prototype by forming a layer filled with an active material on a main surface of a plate-shaped core body; and infiltrating a liquid containing a resin and an organic solvent into at least part of a circumference of the layer filled with the active material. The applied liquid infiltrates into the circumferential region of the active material filling area, namely an outer edge of the layer and an area in its vicinity including the outer edge. The resin contained in the liquid enhances the bonding force between the conductive core body and the active material particles and between the active material particles.