Battery Electrode Sheet Molding to Cut Material Loss and Wrinkles
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Solution Overview
Problem
Existing methods for manufacturing rechargeable battery electrodes suffer from material loss, defects such as wrinkles, and time inefficiencies due to changes in battery type and substrate width, leading to increased defect rates and production delays.
Innovation Solution
A method involving injection molding of a plate-shaped electrode sheet using an electrode mixture, followed by lamination onto a metal substrate, which can be cut and processed in a press device to minimize material loss and defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the conventional coating and notching steps are used to manufacture electrode plates, then the electrode plates can be produced, but material loss occurs in the active material slurry and metal substrate due to derivation of conditions and punching
Solution Approach 1:
The invention changes the physical state and formation parameters of the electrode mixture by using injection molding instead of conventional coating. The electrode mixture is injected in a molten or semi-molten state and then cured to form the electrode plate, eliminating the need for slurry coating and subsequent drying processes that cause material loss.
Solution Approach 2:
The invention replaces the mechanical punching process with a integrated molding approach. The electrode plates are molded with their final shape and size directly in the injection mold, eliminating the need for subsequent punching operations that cause material loss and generate waste.
2Manufacturing precision
If the conventional slitting step is used to cut electrode plates, then the electrode plates can be separated, but wrinkles occur in the uncoated region, increasing the defect rate
Solution Approach 1:
The invention performs the cutting action during the molding process itself. The injection mold includes cutting edges that separate the electrode plates as they are being formed, so the cutting action occurs before the material fully solidifies. This preliminary cutting prevents wrinkles that would otherwise occur during subsequent slitting operations.
Solution Approach 2:
The invention changes the physical state of the electrode mixture during cutting. The material is cut in a semi-molten or pliable state during injection, rather than in a solid, brittle state after complete solidification. This parameter change allows clean cutting without generating wrinkles or defects.
3Adaptability or versatility
If the metal substrate width and coating die are changed to produce different types of rechargeable batteries, then different battery specifications can be produced, but time loss occurs due to changing equipment
Solution Approach 1:
The invention makes the molding system dynamic and adaptable by using programmable injection molding parameters. The injection mold can be quickly reconfigured or the injection parameters (temperature, pressure, injection rate) can be programmatically adjusted to produce different electrode plate specifications without physical equipment changes, enabling rapid production of different battery types.
Solution Approach 2:
The injection molding system serves multiple functions: it forms the electrode mixture, cures the material, and cuts the electrode plates into final shapes, all in a single integrated process. This universal system can produce various electrode plate configurations by changing only the mold configuration or processing parameters, eliminating the need for separate equipment for different battery types.
4Productivity
If the conventional multi-step manufacturing process is used, then the electrode plates can be produced, but the process is time-consuming and results in production delays
Solution Approach 1:
The invention merges multiple conventional manufacturing steps into a single integrated injection molding process. The electrode mixture is injected, formed, cured, and cut all in one continuous operation within the injection mold, eliminating the sequential steps of coating, drying, punching, and slitting that characterize conventional processes.
Solution Approach 2:
The injection molding process maintains continuous useful action throughout the manufacturing cycle. The electrode mixture is continuously injected, formed, and cured without interruption, and the cutting action occurs continuously as the material is being formed. This eliminates the idle time and transitions between discrete steps inherent in conventional batch processing.
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 method reduces material loss and defect rates by ensuring precise lamination and minimizing substrate loss, while also allowing for efficient conversion between different electrode specifications, thereby improving overall production efficiency and quality.
Implementation Method 1
a first step of injection molding a plate-shaped electrode sheet in an injection mold with an electrode mixture that is input into an injection device
Implementation Method 2
the molded electrode sheet may be laminated on one surface of the metal substrate in a press device, and the molded electrode sheet may be laminated to another surface of the metal substrate
Data Source
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AI summary
A method of manufacturing an electrode of a rechargeable battery, the method including a first step of injection molding a plate-shaped electrode sheet in an injection mold with an electrode mixture that is input into an injection device, resulting in a molded electrode sheet, a second step of moving the molded electrode sheet onto a metal substrate and a third step of laminating the metal substrate and the molded electrode sheet.