Multi-Layer Electrode Rolling With Density Gradient Control
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Solution Overview
Problem
Existing methods for manufacturing electrode plates of secondary batteries face challenges in achieving optimal mixture densities for multiple coating layers, leading to increased ionic resistance and degraded cell performance, particularly when symmetrically rolling both lower and upper layers with the same mixture density.
Innovation Solution
A manufacturing process and apparatus that allows for the lower and upper coating layers to have different mixture densities, where the upper layer is rolled at a lower density than the lower layer, optimizing the rolling operations to improve electrode plate quality and reduce ionic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If both lower and upper layers are rolled with the same mixture density, then the manufacturing process is simple and symmetric, but the ionic resistance increases and cell performance degrades
Solution Approach 1:
The patent applies asymmetry by setting different mixture densities for the lower and upper layers during the rolling process. Specifically, the lower layer is rolled at a first mixture density while the upper layer is rolled at a second mixture density that is lower than the first. This asymmetric approach optimizes ionic resistance and cell performance by creating a density gradient that facilitates ion transport, resolving the contradiction between maintaining simple symmetric manufacturing and achieving high reliability.
Solution Approach 2:
The patent implements local quality by assigning different mixture density characteristics to different regions (layers) of the electrode plate. The lower layer and upper layer each have optimized density values tailored to their specific functional requirements within the electrode structure. This allows each layer to possess locally optimized properties that reduce ionic resistance and enhance overall cell performance, rather than applying a uniform density throughout.
2Object-affected harmful factors
If the upper layer is rolled at a lower mixture density than the lower layer, then ionic resistance is reduced and cell performance is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies parameter changes by modifying the mixture density parameter differently for the lower and upper layers during the rolling process. The lower layer is rolled at a first mixture density while the upper layer is rolled at a second mixture density that is lower than the first. This parameter differentiation directly reduces ionic resistance and improves cell performance, while the changes are implemented through standard rolling process adjustments rather than fundamentally new manufacturing steps.
3Manufacturing precision
If symmetric rolling is used for both layers, then the manufacturing process is easier to control, but the electrode plate quality and performance are compromised
Solution Approach 1:
The patent applies asymmetry by configuring the coating apparatus to deposit the upper layer and lower layer with different characteristics that enable subsequent differential rolling. The coating system is designed to accommodate asymmetric density requirements by allowing independent control of coating parameters for each layer, which then enables the upper layer to be rolled at a lower mixture density than the lower layer, achieving high manufacturing precision while managing system complexity.
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 enhances the performance of secondary batteries by reducing ionic resistance and maintaining high capacity, particularly in negative electrodes, thereby improving overall cell efficiency.
Implementation Method 1
a lower-layer roller configured to roll the applied lower layer
Implementation Method 2
an upper-layer roller configured to roll the applied upper layer
Implementation Method 3
a lower-layer coater configured to perform coating a substrate of the secondary battery with a lower layer
Data Source
AI summary
An apparatus for manufacturing an electrode plate of a secondary battery includes a lower-layer coater configured to coat a substrate of the secondary battery with a lower layer, a lower-layer roller configured to roll the lower layer coated on the substrate, an upper-layer coater configured to coat an upper layer on the lower layer rolled on the substrate, and an upper-layer roller configured to roll the upper layer on the lower layer, the upper-layer roller being configured to roll the upper layer at a mixture density lower than a mixture density of the lower layer rolled by the lower-layer roller.