Electrode Web Singulation by Tearing to Reduce Burrs and Spikes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for singulating electrodes from a web material in battery production often result in undesirable burs and spikes that can damage adjacent separator layers due to the application of cutting forces, which is not suitable for battery designs requiring precise alignment and electrical isolation.
Innovation Solution
The method involves fabricating tear lines on the web material and applying a controlled tearing force along these lines to singulate electrodes, using a combination of feed and tear rollers to minimize the production of burs and spikes, and optimizing the perforation pattern to protect the torn edge from contacting adjacent materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cutting forces are applied to singulate electrodes from web material, then electrodes can be separated, but burs and spikes are produced that damage separator layers
Solution Approach 1:
The patent replaces traditional mechanical cutting forces with a tearing mechanism. Tear lines are fabricated on the web material, and electrodes are separated by applying tension to propagate these tear lines, rather than using knives or punches that generate burs and spikes. This substitution of the mechanical separation method eliminates the harmful protrusions while maintaining singulation capability.
Solution Approach 2:
The patent changes the physical state and properties of the web material by fabricating tear lines through perforation or scoring. This pre-weakens the material along specific paths, allowing separation to occur through tearing rather than cutting. The parameter change from intact material to pre-perforated material enables clean separation without generating harmful debris.
2Productivity
If traditional singulation methods are used, then electrodes can be separated, but alignment precision and electrical isolation are compromised
Solution Approach 1:
The patent performs preliminary action by fabricating tear lines on the web material before the actual singulation process. These pre-formed tear lines guide the separation path and ensure that electrodes are torn cleanly along predetermined trajectories, maintaining precise alignment. The preliminary perforation or scoring establishes the separation path in advance, preventing misalignment during the tearing process.
3Productivity
If cutting forces are applied through the material, then electrodes can be singulated, but defects protrude out of the electrode plane
Solution Approach 1:
The patent substitutes cutting mechanics with tearing mechanics. Instead of forcing a blade through the material which creates protruding defects, the process uses tension to propagate tear lines along pre-fabricated paths. This tearing mechanism causes material to separate in-plane rather than creating out-of-plane protrusions, maintaining surface integrity.
Solution Approach 2:
The patent inverts the traditional approach by instead of pushing cutting forces through the material, it pulls the material apart through tension. This inversion of the force application method - from compression/cutting to tension/tearing - fundamentally changes the defect morphology from protruding burrs to clean in-plane separation.
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 approach reduces the occurrence of burs and spikes, ensuring precise alignment and electrical isolation of electrodes, thereby enhancing the efficiency and quality of the battery stacking process.
Implementation Method 1
Because a singulation force is applied along a transport direction of the web, the tension force reduces production of undesirable burs, spikes, and other major surface defects
Data Source
AI summary
Disclosed are techniques for reducing out-of-plane protrusions while singulating an electrode from a web. In some embodiments, feed rollers feed perforated web material from a roll, tear and position rollers receive a portion of the perforated web material from the feed rollers, and a servo motor changes speed of at least one of the feed rollers and tear and position rollers to thereby generate a tearing force, applied to the portion of the perforated web material, that singulates the portion in a predefined shape of an electrode.