Electrode Plate Manufacturing Apparatus Roll Velocity and Contact Angle Control
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Solution Overview
Problem
The existing electrode plate manufacturing methods face defects such as lack of hiding and streaks when using particle aggregates with high solid fractions, leading to non-uniform active material layers in battery electrodes.
Innovation Solution
An electrode plate manufacturing apparatus and method that control the contact angles and velocities of rolls to consolidate and transcribe particle aggregates, ensuring uniform undried active material films are formed on current collector foils, using specific conditions like β−α≥−1.6×B/A+40 and γ−β≥−1.6×C/B+40, and employing plasma processing to adjust roll surface properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If particle aggregates with high solid fraction are used to improve productivity, then manufacturing efficiency increases, but coating uniformity deteriorates causing defects like lack of hiding and streaks
Solution Approach 1:
The patent applies parameter changes by precisely controlling the contact angles (α, β, γ) between roll surfaces and solvent, and by optimizing the velocity ratio (B/A) between rolls. These parameter adjustments enable the system to process particle aggregates with high solid fraction while maintaining coating uniformity and preventing defects like lack of hiding and streaks.
2Productivity
If conveyance velocity is increased to improve productivity, then manufacturing speed increases, but coating quality deteriorates due to insufficient consolidation time
Solution Approach 1:
The patent resolves this contradiction by optimizing the velocity ratio (B/A) between rolls and controlling contact angles. This allows the system to maintain adequate consolidation time and coating quality even at high conveyance velocities, enabling fast production without sacrificing manufacturing precision.
3Quantity of substance
If particle aggregate with high solid fraction is consolidated between rolls, then material density increases, but transcription failure occurs leading to defects
Solution Approach 1:
The patent controls the contact angles (α, β, γ) between roll surfaces and solvent, and optimizes the velocity ratio (B/A). These parameter adjustments ensure proper adhesion and transcription of high-density particle aggregates onto the foil, preventing transcription failure and associated defects while maintaining material density.
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 ensures the formation of uniform undried active material films without defects, improving the productivity and quality of electrode plates by maintaining the desired contact angles and velocity ratios, even with high conveyance velocities.
Implementation Method 1
consolidating a particle aggregate that contains active material particles, a binding agent, a solvent, and granulated wet particles between rolls
Implementation Method 2
the second roll consolidating the particle aggregate between the first roll and the second roll
Implementation Method 3
the third roll transcribing the undried active material film, which is held on the second roll, onto the current collector foil
Implementation Method 4
employing plasma processing to adjust roll surface properties
Data Source
AI summary
An electrode plate manufacturing apparatus includes: a first roll; a second roll that consolidates a particle aggregate and forms an undried active material film; and a third roll that transcribes the undried active material film on the second roll onto a current collector foil. A circumferential velocity A of the first roll, a circumferential velocity B of the second roll, a conveyance velocity C of the current collector foil, a contact angle α of the first roll, a contact angle β of the second roll, and a contact angle γ of the current collector foil satisfy conditions (i) β−α≥−1.6×B/A+40 where β−α>0 and B/A≥1 and (ii) γ−β≥−1.6×C/B+40 where γ−β>0 and C/B≥1.