Non-Rectangular Secondary Battery Electrode Cutting

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Solution Overview

Problem

Conventional methods for manufacturing secondary batteries result in high waste and low manufacturing efficiency due to the large remainder of electrode precursors after cutting out electrodes, which reduces the overall efficiency and increases costs.

Innovation Solution

The method involves forming electrode material layers on metal sheet materials to create electrode precursors and cutting out non-rectangular shaped electrodes, which reduces waste and improves efficiency by allowing for more precise cutting and utilization of materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If rectangular electrodes are cut from electrode precursors using conventional methods, then the cutting process is simple and straightforward, but the remainder after cutout becomes relatively large resulting in low manufacturing efficiency

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidremainder of electrode precursor

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent applies asymmetry by changing the electrode shape from conventional rectangular to non-rectangular forms (such as polygonal shapes with varying side lengths and angles). This asymmetric design allows electrodes to be arranged more efficiently on the precursor sheet, reducing the unused remainder material after cutting while maintaining functional performance.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The patent utilizes dimensional optimization by carefully designing the geometric parameters of non-rectangular electrodes (side lengths, angles, and configurations) to maximize material utilization. This dimensional approach allows multiple electrodes to be arranged in optimized patterns on the precursor sheet, minimizing waste and improving manufacturing efficiency.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Loss of substance

If non-rectangular electrodes are used, then the utilization of electrode precursor material is improved, but the cutting process becomes more complex

Engineering Contradiction:

Improvewaste of electrode precursorVSAvoidcutting process complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent segments the electrode precursor into multiple non-rectangular electrode shapes that can be systematically arranged and cut. By dividing the precursor into defined geometric segments with specific configurations, the cutting process becomes more organized and manageable, reducing complexity while improving material utilization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies preliminary action by pre-designing and pre-positioning the non-rectangular electrode patterns on the electrode precursor before cutting. This preliminary arrangement optimizes the layout to minimize remainder material, and the pre-defined geometric patterns facilitate a more straightforward cutting process despite the non-rectangular shapes.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11329273B2Method for manufacturing secondary battery

Publication Date: 2022.05.10 MURATA MFG CO LTD

AI summary

A method for manufacturing a secondary battery in which the preparation of at least one of a positive electrode and ta negative electrode includes forming an electrode material layer on a metal sheet material to serve as an electrode current collector, thereby providing an electrode precursor, and cutting out electrodes from the electrode precursor to form a plurality of electrodes. Each of the electrodes has a non-rectangular shape.