Electrode Plate Manufacturing Using Roll Removal for Region Definition
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Solution Overview
Problem
Conventional electrode plate manufacturing methods face challenges in producing high-quality electrode plates with distinct formation and non-formation regions on a current collector foil, as the division plate required to separate these regions can damage the foil and roll components, leading to non-uniform active material layer formation.
Innovation Solution
The method employs a configuration with a first and second roll rotating in opposite directions, a removal portion with a projecting portion to remove excess active material layer from the non-formation region, and a third roll to convey and pressurize the current collector foil, ensuring uniform active material layer formation on the foil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a division plate is provided to separate formation region and non-formation region, then the boundary between regions can be defined, but the current collector foil or press roll may be damaged
Solution Approach 1:
The harmful division plate is completely removed from the system. Instead, a removal portion is provided on the second roll that selectively removes active material layer only in the non-formation region, achieving region separation without physical contact that could damage components
Solution Approach 2:
The active material layer itself serves as an intermediary medium. By controlling its presence and removal, the boundary between formation and non-formation regions is defined without requiring a physical division plate that could damage the current collector foil or press roll
2Manufacturing precision
If the division plate makes contact with the current collector foil to prevent powder leakage, then the boundary between regions can be maintained, but the current collector foil may be damaged
Solution Approach 1:
The division plate is completely removed from the system. The removal portion on the second roll selectively removes active material layer in the non-formation region, achieving leakage prevention without physical contact that could damage the current collector foil
Solution Approach 2:
The system uses the active material layer itself and the removal portion to define and maintain the boundary between formation and non-formation regions, eliminating the need for an external division plate that would require contact with the current collector foil
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 configuration allows for the production of high-quality electrode plates with well-defined formation and non-formation regions, maintaining the integrity of the current collector foil and achieving uniform active material layer thickness and quality.
Implementation Method 1
pressurizing the active material layer material supplied from the supply portion by the first roll and the second roll both rotating while the active material layer material passes the first position, thereby forming the active material layer such that the active material layer material thus pressurized is attached onto the second roll
Implementation Method 2
conveying the current collector foil by the rotating third roll so as to pass the second position, thereby pressurizing, in the thickness direction, the current collector foil and the active material layer passing the second position between the second roll and the third roll and transferring the active material layer onto the surface of the current collector foil from the second roll
Data Source
AI summary
At a first position, an active material layer material is pressurized by first and second rolls, so as to form an active material layer on the second roll. Further, at a third position on a downstream side relative to the first position but on an upstream side relative to, in a rotation direction of the second roll, a second position where a third roll is opposed to the second roll, a part corresponding to a non-formation region in the active material layer is pressurized between a removal surface of the removal portion and the second roll, thereby transferring the pressurized part to the removal surface from the second roll so as to remove the pressurized part. Further, at the second position, the active material layer is transferred onto a surface of a current collector foil from the second roll.