Traversing Roller Profile for Wrinkle-Free Electrode Calendering
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Solution Overview
Problem
The rolling process of electrode plates in secondary batteries leads to compression deviations due to thickness differences between coated and uncoated portions, causing unbalanced plastic deformation, residual stress, and potential breakage during subsequent processes.
Innovation Solution
An electrode manufacturing apparatus using a traversing roller system with a first and second roller, where the second roller's diameter is larger at the center than at the ends, allowing for a non-contact region and controlled meandering to minimize stress concentration and prevent breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional rolling roll is used to traverse the electrode substrate, then the coated portion can be pressed, but the uncoated portion generates wrinkles and residual stress due to thickness difference
Solution Approach 1:
The traversing roller is designed with different diameters at different positions: the first roller has a diameter matching the coated portion thickness, while the second roller has a larger diameter that creates a non-contact region for the uncoated portion. This local differentiation allows the coated portion to be pressed uniformly while the uncoated portion is avoided, preventing wrinkles and residual stress.
Solution Approach 2:
The traversing roller is segmented into two distinct rollers (first roller and second roller) with different diameters. The first roller corresponds to the coated portion and the second roller corresponds to the uncoated portion, allowing each segment to handle the respective portion appropriately without causing harm to either region.
2Device complexity
If the traversing roller has uniform diameter, then the structure is simple, but stress concentration occurs at the boundary between coated and uncoated portions
Solution Approach 1:
The traversing roller is designed with asymmetric diameter distribution: the first roller has a smaller diameter corresponding to the coated portion, while the second roller has a larger diameter creating a non-contact region for the uncoated portion. This asymmetric design prevents stress concentration at the boundary between coated and uncoated portions, thereby improving fracture resistance.
3Device complexity
If the second roller contacts the uncoated portion, then the traversing roller structure is simple, but compression deviation occurs due to thickness difference
Solution Approach 1:
The second roller is designed with a larger diameter than the first roller, creating a non-contact region that locally avoids the uncoated portion. This local quality differentiation ensures that compression is applied only to the coated portion with uniform thickness, preventing compression deviation while maintaining a relatively simple overall traversing roller configuration.
Data Source
AI summary
An electrode manufacturing apparatus according to one embodiment is an electrode manufacturing apparatus that traverses an electrode substrate having a coated portion and an uncoated portion. The apparatus includes: a traversing roller that traverses the electrode substrate, wherein the traversing roller includes a first roller, and a second roller surrounding an outer surface of the first roller, and wherein a diameter of a central part of the second roller is larger than a diameter of one end part of the second roller.