Segmented Electrode Support Roll for Uncoated Edge Wrinkle Control

Solution Overview

Problem

Wrinkles and folds occur in the uncoated portions of electrode sheets during the manufacturing process due to thickness differences between coated and uncoated areas, leading to inefficiencies and reduced productivity.

Innovation Solution

An electrode supporting roll with a main roll and press portion that includes sub-rolls and a height-adjustable press roll, allowing for variable tension application to prevent wrinkles by adjusting the position and height of sub-rolls to match the uncoated portions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional electrode supporting roll is used, then the electrode sheet can be supported during manufacturing, but wrinkles and folds occur in the uncoated portion due to thickness difference between coated and uncoated portions

Engineering Contradiction:

Improveprevention of wrinkles and foldsVSAvoidstructure of supporting roll

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The supporting roll is divided into multiple independent sub-rolls (first sub-roll, second sub-roll, third sub-roll) that can be individually adjusted. This segmentation allows each sub-roll to independently apply tension to different portions of the electrode sheet, specifically targeting the uncoated portion to prevent wrinkles without affecting the coated portions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first sub-roll is positioned to contact only the uncoated portion of the electrode sheet, applying localized tension precisely where the thickness difference causes wrinkling. This local quality approach ensures that tension is applied only where needed, preventing wrinkles in the uncoated portion while maintaining proper support for the coated portions.

Inventive Principle:

Principle #3Local quality

2Reliability

If tension is applied to the uncoated portion to prevent wrinkles, then wrinkle prevention is achieved, but the device requires adjustable mechanisms increasing complexity

Engineering Contradiction:

Improveprevention of wrinkles and foldsVSAvoidadjustability of sub-rolls

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The supporting roll system incorporates adjustable mechanisms that allow the sub-rolls to be dynamically repositioned. The first sub-roll can be adjusted in the width direction to contact different portions of the uncoated portion, and the height of sub-rolls can be adjusted to control the degree of tension applied. This dynamics enables adaptation to various electrode sheet configurations and uncoated portion positions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The adjustable mechanisms are designed to enable operators to easily configure the sub-rolls according to the specific electrode sheet being processed. The system allows for quick adjustment of sub-roll positions and heights without requiring complex reconfiguration, making the device user-friendly and adaptable to different production requirements.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If multiple sub-rolls are used to apply variable tension, then wrinkle prevention is improved, but the manufacturing complexity of the roll increases

Engineering Contradiction:

Improvecontrol of electrode sheet tensionVSAvoidnumber of sub-rolls and adjustment mechanisms

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The supporting roll is divided into multiple independent sub-rolls (first sub-roll, second sub-roll, third sub-roll) that can be individually adjusted. This segmentation allows each sub-roll to independently apply tension to different portions of the electrode sheet, specifically targeting the uncoated portion to prevent wrinkles without affecting the coated portions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first sub-roll is positioned to contact only the uncoated portion of the electrode sheet, applying localized tension precisely where the thickness difference causes wrinkling. This local quality approach ensures that tension is applied only where needed, preventing wrinkles in the uncoated portion while maintaining proper support for the coated portions.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12620614B2Roll for supporting electrode and electrode manufacturing apparatus including the same

Publication Date: 2026.05.05 LG ENERGY SOLUTION LTD

AI summary

An electrode supporting roll according to an embodiment of the present invention supports an electrode sheet, and includes: a main roll that includes a plurality of sub-rolls rotatably coupled to a single first shaft, while being in contact with the electrode sheet; and a press portion that is positioned at the opposite side of the electrode, while disposing the main roll therebetween, and reciprocally moves to push at least one of the plurality of sub-rolls toward the electrode sheet.