Flexible Electrode Sheet Splicing for Roll-to-Roll Tension Control
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Solution Overview
Problem
Conventional electrode sheet connection methods in roll-to-roll processes face issues with stress concentration and meandering movement, leading to increased defect rates and reduced device operation efficiency due to inconsistent tension and potential breakage at the connection points.
Innovation Solution
A flexible connection sheet of predetermined length is arranged between electrode sheets, connected using tapes only on coated portions, to relieve stress and adjust meandering movement, utilizing materials like PET, PEN, OPP, PI, PBT, polyester, polyamide, polyethersulfone, polyphenyleneoxide, polyphenylene sulfide, polyethylenenaphthalene, or flexible silicon.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electrode sheets are connected directly using tape in conventional roll-to-roll process, then connection simplicity is maintained, but stress concentration occurs at connection points leading to increased fracture risk
Solution Approach 1:
A flexible buffer sheet is introduced as an intermediary component between the first and second electrode sheets. This buffer sheet absorbs stress and prevents direct stress transmission to the tape connection points, thereby reducing fracture risk while maintaining connection simplicity.
Solution Approach 2:
The flexible buffer sheet is made from flexible materials such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN), oriented polypropylene (OPP), or polyimide (PI). These flexible thin films can deform to absorb stress, preventing stress concentration at the connection points between electrode sheets.
2Productivity
If electrode sheets are connected with fixed tension, then manufacturing efficiency is maintained, but meandering movement cannot be adjusted leading to positioning errors
Solution Approach 1:
The buffer sheet provides dynamic adjustment capability for meandering movement of electrode sheets. While the overall tension maintains manufacturing efficiency, the flexible buffer sheet allows local adjustments to accommodate meandering, enabling both high productivity and positioning accuracy.
3Strength
If tape is attached on both coated and non-coated portions of electrode sheet, then connection strength is maximized, but electrode sheet breakage occurs due to stress on non-coated portions
Solution Approach 1:
The tape is selectively attached only on the coated portions of the electrode sheets, where the electrode slurry provides additional adhesion. The buffer sheet spans the non-coated portions, distributing stress away from these vulnerable areas. This local differentiation of attachment strategy maximizes connection strength while preventing breakage.
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
Significantly reduces fracture risk at connection points and provides a margin for adjusting meandering movement, enhancing the stability and efficiency of the roll-to-roll process by absorbing tension and facilitating easy detection of connection points.
Implementation Method 1
a flexible connection sheet of a predetermined length, which is arranged between a first electrode sheet and a second electrode sheet
Implementation Method 2
connecting the first electrode sheet to the flexible connection sheet by attaching one side of the first electrode sheet to one side of the flexible connection sheet using a first tape
Data Source
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AI summary
The present technology relates to a method for connecting electrode sheets in a roll-to-roll process, and the method includes: arranging a flexible connection sheet of a predetermined length between a first electrode sheet and a second electrode sheet; connecting the first electrode sheet to the flexible connection sheet by attaching one side of the first electrode sheet to one side of the flexible connection sheet using a first tape; and connecting the second electrode sheet to the flexible connection sheet by attaching one side of the second electrode sheet to the other side of the flexible connection sheet using a second tape. Further, the present technology relates to an electrode sheet manufactured by manufactured by the method of connecting electrode sheets.