Electrode Tab Air Guidance on Transfer Rollers to Prevent Folding
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Solution Overview
Problem
The folding and migration of electrode tabs during the transfer process in secondary batteries lead to manufacturing defects, reducing yield and causing economic losses.
Innovation Solution
An electrode transfer system with a guide roller and a tab guide unit that uses air suction and jetting to stabilize electrode tabs, employing a guide member with alternating suction and jet holes to prevent tab deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If electrode tabs are processed to very small thickness to reduce material usage and improve battery performance, then energy density and efficiency are improved, but the electrode sheet becomes prone to folding and breaking during transfer
Solution Approach 1:
The patent applies pneumatic principles by using air blowers to generate controlled air flows that lift and stabilize electrode tabs during transfer. Air nozzles are positioned to direct air streams beneath the tabs, creating an air cushion that prevents contact with the transfer surface, thereby eliminating folding and breaking while maintaining the benefits of thin tab design
Solution Approach 2:
The patent introduces air as an intermediary medium between the electrode tabs and the transfer surface. This air layer acts as a mediator that supports the thin tabs during transfer without requiring direct mechanical contact, thus preventing damage while allowing the use of minimal thickness tabs for improved energy density
2Measurement precision
If manual detection of electrode tab defects is performed to identify folding and migration, then defect detection capability is improved, but production efficiency decreases due to operator workload and inability to detect all defects
Solution Approach 1:
The patent replaces the manual mechanical detection system with an automated optical detection system. Cameras or sensors are positioned to capture images of electrode tabs during transfer, and image processing algorithms automatically identify folding and migration defects, eliminating the need for manual inspection while improving both detection accuracy and production efficiency
Solution Approach 2:
The detection system is designed to automatically identify and flag defective tabs without requiring operator intervention. The system performs self-inspection by capturing images, processing them through algorithms, and marking defective tabs for removal, thereby maintaining high production efficiency while achieving comprehensive defect detection
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
Effectively prevents electrode tab folding and migration, enhancing production yield by maintaining tab integrity during transfer.
Implementation Method 1
a pump unit connected to the hole to be in communication and to provide a suction force and a jet force to the guide member
Implementation Method 2
a pump unit connected to the hole to be in communication and to provide a suction force and a jet force to the guide member
Data Source
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AI summary
Disclosed herein relates to an electrode transfer system for transferring electrode sheets that include electrode tabs formed at predetermined spacings on one side, including: a guide roller configured to rotate along a transfer direction of the electrode sheet and supporting the electrode sheet; and a tab guide unit configured to blow air or suck air toward opposing electrode sheets on the guide roller, wherein the tab guide unit includes: a guide member including at least one hole formed to allow air to flow in and out, and extending along a curved surface of the guide roller; and a pump unit connected to the hole to be in communication and to provide a suction force and a jet force to the guide member.