Non-Rectangular Electrode Coating for Secondary Battery Efficiency
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Solution Overview
Problem
The manufacturing efficiency of non-rectangular electrodes in secondary batteries is reduced due to a significant surplus portion of the electrode precursor that cannot be reused, leading to increased discard amounts and decreased overall efficiency.
Innovation Solution
A novel coating method where the shape of the electrode material layer raw material's coating surface is altered to match the non-rectangular electrode shape, allowing for reduced surplus portions during cutting, thereby improving manufacturing efficiency by utilizing the cutoff portions as metal sheet material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a metal sheet material is coated with an electrode material layer raw material to form an electrode precursor and then cut to obtain non-rectangular electrodes, then non-rectangular electrodes can be manufactured, but a large surplus portion is generated that cannot be reused, leading to decreased manufacturing efficiency
Solution Approach 1:
The patent applies preliminary action by changing the shape of the coating surface of the electrode material layer raw material to match the non-rectangular electrode shape before cutting. This preliminary shaping of the coating surface ensures that when the electrode precursor is cut, the surplus portion is minimized because the coating material already conforms to the final electrode geometry, allowing the cutoff portions to be effectively utilized as metal sheet material.
2Shape
If the electrode precursor is cut to form non-rectangular electrodes, then the desired electrode shape is achieved, but the amount of surplus portion that must be discarded increases
Solution Approach 1:
The patent applies local quality by making the coating surface shape different from the conventional rectangular shape and matching it to the non-rectangular electrode shape. This localized shaping of the coating surface ensures that material is applied only where needed for the final electrode geometry, reducing waste of the electrode material layer raw material in the surplus portions that would otherwise be discarded.
3Ease of manufacture
If a conventional coating method is used to form an electrode precursor, then the coating process is simple, but the manufacturing efficiency of non-rectangular electrodes decreases due to large surplus portions
Solution Approach 1:
The patent applies dynamics by making the coating surface shape changeable or adaptable to match the non-rectangular electrode shape. This dynamic adjustment of the coating surface configuration allows the coating process to accommodate complex electrode geometries while maintaining manufacturing efficiency, as the coating system can be modified to deposit material in the precise pattern needed for the final electrode shape.
Data Source
AI summary
A manufacturing method for a secondary battery that includes coating a metal current collector sheet material with an electrode material layer raw material such that a shape of a coating surface of the electrode material layer raw material is changed based on a shape of a non-rectangular electrode to be formed to form an electrode precursor, and cutting the electrode precursor into a non-rectangular electrode shape.