Extruder Die for Laminated Structure Manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing laminated structures, such as electrode laminated bodies, require complex mechanisms that can lead to lamination failures like winding deviation due to the complexity of the electrode group extruder die device.
Innovation Solution
A method using an extruder die with specific conveyance paths for raw materials, where the core layer, first surface layer, and second surface layer materials merge at an ejection port, allowing for the formation of a laminated structure with stable layer thicknesses without contact with the downstream portion of the die, utilizing viscous fluids and controlled pressure differences to prevent deformation and ensure accurate layer stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complex electrode group extruder die device with multiple chucks and guide rails is used to apply back tension and prevent winding deviation, then lamination stability is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the complex chuck and guide rail mechanism from the extruder die device. Instead of using multiple chucks (two pairs for separator, one each for electrodes) with guide rails to apply back tension, the invention uses a simplified die structure where the separator and electrodes are extruded and laminated without requiring these additional mechanical components, thereby reducing device complexity while maintaining lamination stability
Solution Approach 2:
The patent merges the functions of multiple separate chucks and guide rails into a single integrated extrusion process. The separator and electrode materials are extruded through a unified die structure with integrated conveyance paths, combining the functions of tension control, positioning, and lamination into one streamlined mechanism, thus reducing the number of components while achieving the same lamination stability
2Reliability
If multiple chucks with guide rails are used to hold and tension sheet elements during winding, then winding deviation is prevented, but the number of components increases
Solution Approach 1:
The patent removes the multiple chucks and guide rails from the system. Instead of using these separate components to hold and tension the sheet elements during winding, the invention achieves winding accuracy through a different approach: the separator and electrodes are extruded as continuous laminated structures directly from the die, eliminating the need for discrete chuck-based tensioning mechanisms
Solution Approach 2:
The patent replaces the mechanical chuck and guide rail system with an extrusion-based lamination process. Rather than using mechanical tensioning devices to control winding accuracy, the invention uses controlled extrusion of viscous materials through a die with specific geometry, where the material flow and die structure itself ensure proper alignment and prevent deviation
3Device complexity
If a simple extrusion process is used without back tension mechanism, then device complexity is reduced, but winding deviation may occur
Solution Approach 1:
The patent uses the viscous flow properties of the extruded materials (electrode paste and separator paste) as a fluid-like system to achieve lamination. The controlled extrusion of these viscous materials through the die creates inherent tension and alignment during the extrusion process itself, replacing the need for separate mechanical back tension mechanisms while maintaining lamination accuracy
Solution Approach 2:
The patent changes the state of the materials to viscous pastes during extrusion, allowing them to be shaped and laminated in a semi-fluid state. This parameter change enables the materials to conform to the die geometry and maintain proper alignment during extrusion, achieving lamination accuracy without requiring complex tensioning mechanisms that would be needed for rigid sheets
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 simplifies the manufacturing process, prevents lamination failures like winding deviation, and ensures stable thicknesses and adhesion of layers, enhancing the performance of the resulting laminated structure, such as electrode laminated bodies for batteries.
Implementation Method 1
causing a viscous fluid as the raw material of the first surface layer, a viscous fluid as the raw material of the second surface layer, and a viscous fluid as the raw material of the core layer to flow into the first surface layer material conveyance path, the second surface layer material conveyance path, and the core layer material conveyance path, respectively
Implementation Method 2
the core layer material conveyance path, the first surface layer material conveyance path and the second surface layer material conveyance path merge at the ejection port; the laminated structure in which the raw material of the first surface layer, the raw material of the core layer, and the raw material of the second surface layer are stacked in a layered manner is ejected from the ejection port
Implementation Method 3
the extruder die has a shape in which a downstream portion does not contact the ejected laminated structure formed of the raw materials, the downstream portion being downstream of a merging location that is the ejection port, with respect to flow of the raw materials
Data Source
AI summary
A laminated structure is manufactured using an extruder die in which an ejection port is provided, the laminated structure including a core layer, a first surface layer, and a second surface layer. The extruder die includes a first surface layer material conveyance path through which a raw material of the first surface layer is conveyed, a second surface layer material conveyance path through which a raw material of the second surface layer is conveyed, and a core layer material conveyance path through which a raw material of the core layer is conveyed. The paths merge at the ejection port. The extruder die has a shape in which a downstream portion downstream of a merging location that is the ejection port does not contact the injected laminated structure formed of the raw materials. The laminated structure is injected by causing viscous fluids as the raw materials into the paths, respectively.