Electrode Sheet Manufacturing via Differential Roll Shear
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Solution Overview
Problem
Conventional methods for manufacturing electrode sheets with high-density electrode layers require large and complex facilities due to the need for high-pressure rolls, which complicates the manufacturing process.
Innovation Solution
A method and apparatus that utilize a press roll pair with inner and outer rolls rotating at different speeds to apply both press load and shear force, allowing for higher compression of electrode layers without excessive facility enlargement, enabling the production of electrode sheets with high-density and homogeneous layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-pressure rolls are used to increase electrode layer density, then manufacturing precision is improved, but device complexity and facility size increase
Solution Approach 1:
The patent applies dynamic speed differential between inner and outer rolls to create shear force for compression. The inner roll rotates at a different speed than the outer roll, generating relative motion that produces shear force on the electrode layer. This dynamic approach replaces static high-pressure rolling with a more efficient shear-based compression mechanism, achieving high density without requiring excessively large or complex facilities.
2Manufacturing precision
If heating function is added to rolls to enhance electrode layer density, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces thermal processing (heating) with mechanical shear force generated by speed differential between rolls. Instead of using heat to enhance density, the invention uses the mechanical shear force from differential rotation to achieve compression. This substitution eliminates the need for heating systems while maintaining or improving density, thereby reducing facility complexity.
3Manufacturing precision
If high load is applied to press rolls to increase electrode layer density, then manufacturing precision is improved, but the facility size must be enlarged
Solution Approach 1:
The patent changes the compression mechanism from high-load static pressing to shear force generation through speed differential. By altering the operational parameters from high pressure to differential velocity, the system achieves effective compression with smaller, more compact equipment. This parameter change allows high density to be achieved without proportionally increasing facility size.
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 allows for the production of electrode sheets with high-density and homogeneous electrode layers while maintaining a compact and simplified manufacturing facility, enhancing the efficiency and quality of the electrode sheets.
Implementation Method 1
causing a press roll pair including a pair of rolls to contact with the original electrode sheet from both sides... to form the unfinished electrode layers into electrode layers... the rolls of the press roll pair are driven by the driving part to rotate such that a moving speed of cylindrical surface of an inner roll... is higher than a moving speed of cylindrical surface of an outer roll
Data Source
AI summary
A method for manufacturing an electrode sheet including an electrode layer on both surfaces of a current collecting foil includes: feeding out an original electrode sheet including an unfinished electrode layer on each surface of the foil from a feeding part; causing a press roll pair to contact with the original sheet fed out to form the unfinished layers into electrode layers; receiving the sheet having passed through the roll pair by a sheet receiving part; and rotating rolls of the roll pair in a feeding direction. The feeding part, roll pair, and receiving part are placed such that the original sheet and the electrode sheet are to be wound on one of the rolls. The rolls are rotated such that a moving speed of cylindrical surface of one roll placed in a position where the sheets are wound thereon is higher than that of the other roll.