Perforated Current Collector Manufacturing Process
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Solution Overview
Problem
The manufacturing process of electrodes with perforated current collectors faces challenges in productivity and cost due to the need to lift the current-collector material vertically, which limits conveying speed and increases the risk of material breakage, and the formation of smaller through-holes, which reduces ion mobility and prolongs lithium doping, thereby decreasing productivity and increasing costs.
Innovation Solution
A manufacturing process that includes forming protection layers on the current-collector material, using polyvinylidene fluoride, and applying the electrode slurry without removing the protection layers initially, allowing horizontal conveyance and heat treatment to absorb and remove the protection layers, preventing slurry leakage and enhancing tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the current-collector material is lifted up in the vertical direction to apply electrode slurry, then the deposition of electrode slurry onto guide roller is prevented, but the conveying speed is lowered and productivity decreases
Solution Approach 1:
Instead of lifting the current collector vertically to prevent slurry leakage, the patent inverts the approach by forming through-holes in the current collector to allow controlled passage of slurry, eliminating the need for vertical lifting while maintaining productivity through horizontal conveyance
2Reliability
If the current-collector material is lifted up in the vertical direction, then slurry leakage is prevented, but the current-collector material may be broken by its own weight
Solution Approach 1:
Rather than relying on vertical lifting to prevent slurry leakage, the patent creates through-holes in the current collector that enable controlled slurry passage, eliminating the need for height increases that would risk material breakage
Solution Approach 2:
The patent introduces a protection layer as an intermediary substance that fills the through-holes during slurry application, preventing slurry leakage while allowing the current collector to maintain its horizontal conveyance position without excessive lifting
3Reliability
If smaller through-holes are formed on the current-collector material, then electrode slurry leakage is prevented, but the moving speed of lithium ions is lowered
Solution Approach 1:
The patent optimizes the parameters of through-holes (size, shape, distribution) to achieve a balance where slurry leakage is prevented while maintaining sufficient aperture for rapid lithium ion movement, rather than simply reducing hole size
4Reliability
If smaller through-holes are formed, then slurry leakage is prevented, but the doping operation time is prolonged
Solution Approach 1:
The patent adjusts through-hole parameters (size, shape, distribution) to optimize the balance between preventing slurry leakage and maintaining rapid lithium ion diffusion, reducing doping time while ensuring proper slurry application
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 process enhances electrode productivity by allowing faster conveying speeds, preventing material breakage, and maintaining lithium ion mobility, while reducing manufacturing costs and improving energy density of electric storage devices.
Implementation Method 1
a protection layer formation step in which a protection layer spreading on one surface of a current-collector material is formed while a protection layer having a predetermined pattern is formed on the other surface of the current-collector material; an etching step for performing an etching process on the current-collector material from the surface on which the protection layers having the predetermined pattern is formed so as to form through-holes on the current-collector material
Implementation Method 2
a protection layer removing step for removing the protection layers from the current-collector material having the electrode mixture layer
Data Source
AI summary
A resist layer is formed over one surface of a current-collector material, while a resist layer having a predetermined pattern is formed on the other surface of the current-collector material. Through-holes are formed on the current-collector material through an etching process. An electrode slurry is applied onto the current-collector material formed with the through-holes without removing the resist layers. Specifically, since the through-holes are closed by the resist layer, the electrode slurry does not pass through the through-holes to leak out. Therefore, the current-collector material can be conveyed in the horizontal direction, whereby the productivity of an electrode can be enhanced. The resist layers are made of PVdF, and the resist layers are removed in a heating and drying step in which the PVdF is dissolved.