Dry Electrode Sheet Window Geometry for Current Collector Exposure
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Solution Overview
Problem
Conventional methods for manufacturing electrode sheets in power storage apparatuses, such as secondary batteries and capacitors, lack efficiency in forming window portions for current collector exposure, leading to potential quality issues and reduced capacity.
Innovation Solution
A molding apparatus with a cutting jig and removal pad system is used to create window portions in the compound sheet, ensuring the current collector plate is exposed in a controlled manner, with specific angle constraints to enhance the quality and capacity of the power storage apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to manufacture electrode sheets, then the manufacturing process is simpler, but the quality and capacity of power storage apparatuses are reduced due to improper window portion formation
Solution Approach 1:
The molding apparatus is divided into distinct functional components: a cutting jig with multiple blades for precise window portion formation, and a removal pad for clean-up operations. This segmentation allows each component to perform its specific function optimally, achieving high manufacturing precision without requiring the entire system to be overly complex.
Solution Approach 2:
The cutting jig performs preliminary cutting actions to create the window portions in the compound sheet before final assembly. By pre-forming the window portions with specific angle requirements (75°-105°) during the molding process itself, the need for subsequent complex processing is reduced, improving overall manufacturing precision.
2Manufacturing precision
If the window portion is not formed with precise angle control, then the manufacturing process is faster, but the current collector plate exposure is improper, reducing power storage apparatus quality
Solution Approach 1:
The cutting jig is designed to automatically form window portions with the required angle characteristics (75°-105°) during the normal molding process without requiring additional measurement or adjustment steps. The geometry of the cutting blades themselves ensures the correct angles are achieved, making the process self-regulating and maintaining both precision and productivity.
Solution Approach 2:
The invention specifies precise angular parameters (75°-105°) for the window portion formation. By controlling this geometric parameter during the molding process, the current collector plate exposure is optimized for both quality and subsequent processing efficiency, balancing manufacturing precision with productivity.
3Reliability
If the compound sheet is not properly cleaned after window portion formation, then the process is faster, but debris interferes with current collection, reducing power storage apparatus performance
Solution Approach 1:
The cutting and cleaning operations are merged into a single integrated molding process. The cutting jig creates window portions while the removal pad simultaneously performs clean-up of debris. This combination ensures reliable current collection by removing interfering debris without requiring separate cleaning steps, maintaining both reliability and productivity.
Solution Approach 2:
The removal pad acts as an intermediary element between the cutting operation and the final product. It captures and removes debris generated during window portion formation, preventing contamination of the current collector plate exposure area. This intermediary function ensures current collection reliability while keeping the cleaning process integrated and efficient.
Data Source
AI summary
An electrode sheet includes a current collector plate and a compound sheet comprised of a dry electrode compound and layered on a surface of the current collector plate. The compound sheet includes a window portion surrounded by the dry electrode compound over an entire circumference, and the current collector plate is exposed in the window portion. An angle formed by a side wall of the compound sheet in the window portion and a surface of the current collector plate is 75° or more and 105° or less in a cross-section perpendicular to a direction of extension of the current collector plate and the compound sheet.