Electrode Sheet Coating Layout for Laser-Free Tab Welding Slots
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Solution Overview
Problem
The high manufacturing costs of electrode sheets in battery cells are attributed to the costly laser cleaning process required to form tab welding grooves in the active material layer.
Innovation Solution
A method of manufacturing electrode sheets that constructs tab welding grooves through coating without laser cleaning, using multiple layers of active materials to define the groove, reducing the need for laser cleaning and associated costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser cleaning is used to form tab welding groove, then the groove is formed precisely, but manufacturing cost increases
Solution Approach 1:
The patent applies preliminary action by pre-defining the tab welding groove pattern during the coating process itself. The coating mask is designed with groove patterns that are directly imprinted onto the active material layer during coating, eliminating the need for subsequent laser cleaning. This preliminary formation of the groove structure resolves the contradiction by achieving precise groove formation through the coating step rather than requiring expensive post-processing laser cleaning.
2Ease of manufacture
If traditional coating method is used, then coating process is simple, but tab welding groove cannot be formed
Solution Approach 1:
The patent applies universality by making the coating process perform multiple functions: it simultaneously deposits the active material layer and defines the tab welding groove pattern in one operation. The coating mask serves dual purposes of material application and groove formation, combining what were previously separate processes (coating and groove formation) into a single multi-functional step, thus maintaining simplicity while achieving groove formation.
Solution Approach 2:
The patent uses a coating mask as an intermediary tool that transfers the groove pattern onto the active material layer during coating. This mask acts as a mediator between the coating process and the desired groove structure, enabling the simple coating process to produce the complex groove pattern without requiring additional processing steps.
3Manufacturing precision
If laser cleaning is used, then active material layer is removed to form groove, but production time increases
Solution Approach 1:
The patent eliminates production time loss by performing groove formation preliminarily during the coating process itself. The groove pattern is defined in the same step that the active material layer is deposited, rather than requiring a separate post-coating laser cleaning step. This integration of groove formation into the coating process resolves the time consumption issue while maintaining precise groove formation.
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 manufacturing costs by eliminating the need for laser cleaning, improves coating efficiency, and enhances productivity by allowing simultaneous formation of multiple electrode sheets.
Implementation Method 1
coating a to-be-coated surface of a current collector with a first active material to form a first film layer
Data Source
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AI summary
An electrode sheet manufacturing method and a coating apparatus. The electrode sheet manufacturing method comprises the steps of: coating a surface to be coated of a current collector with a first active material so as to form a first film layer; coating said surface with a second active material to form a second film layer; coating said surface with a third active material so as to form a third film layer; and after the first film layer, the second film layer and the third film layer are all formed, the second film layer and the third film layer being both connected to the first film layer, the second film layer and the third film layer being sequentially distributed at intervals in a first direction, the second film layer and the third film layer being located on the same side of the first film layer, and the first film layer, the second film layer, the third film layer and said surface jointly defining a tab welding slot. In the method, the tab welding slot is manufactured by coating, without the need to manufacture the tab welding slot by laser cleaning, and the method is beneficial to reducing the manufacturing cost of electrode sheets.