Powder Transfer Rollers for Dry Electrode Plate Forming
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Solution Overview
Problem
Conventional electrode plate production methods require electrical drying of slurry electrode materials, leading to high electrical power consumption, and there is a need to process electrode materials into a desired shape without changing them from a powder form to a slurry.
Innovation Solution
A powder transfer roller device and method that uses a first roller with raised portions and a second roller with a flat or recessed surface to compact and transfer powder to a sheet member, maintaining the powder state and allowing for molding into a desired shape, with the second roller rotating faster than the first and the sheet member moving faster than the second roller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrical drying method is used to dry slurry electrode materials, then the electrode materials can be processed into electrode plates, but electrical power consumption increases significantly
Solution Approach 1:
The invention changes the physical state parameter of electrode materials from slurry to powder form, eliminating the need for thermal drying process. By using powder materials that can be directly compacted and bound, the process avoids high energy consumption associated with evaporating solvent from slurry while still achieving solid electrode plate formation.
Solution Approach 2:
The invention extracts and eliminates the drying step from the conventional electrode manufacturing process. By removing the need for solvent-based slurry and its subsequent drying, the process directly uses compacted powder materials to form electrodes, thereby taking out the high energy-consuming thermal drying operation from the production flow.
2Ease of manufacture
If slurry electrode materials are used, then electrode plates can be formed, but the electrode materials must be changed from powder form to slurry
Solution Approach 1:
Instead of converting powder to slurry as in conventional processes, the invention inverts the approach by using powder materials directly without conversion to slurry form. The process binds and compactes powder particles directly to form electrodes, eliminating the need for solvent mixing and subsequent drying steps required in slurry-based manufacturing.
Solution Approach 2:
The invention changes the material state parameter from slurry (liquid-based) to powder (solid-based) form. This parameter change allows direct compaction and binding of electrode materials without requiring solvent removal, thereby maintaining powder form integrity throughout the manufacturing process while still achieving electrode plate formation.
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 enables the production of electrode plates from powder materials without the need for electrical drying, significantly reducing power consumption and allowing for the molding of powdery materials into desired shapes while keeping them in a powder state.
Implementation Method 1
a second roller which is opposed to the first roller and which compacts, between the raised portion of the first roller and the second roller, powder supplied between the first roller and the second roller
Implementation Method 2
transferring the powder adhering to the second roller to a sheet member that moves so as to contact the second roller
Implementation Method 3
the second roller rotating at a circumferential velocity greater than a circumferential velocity of the first roller in the step (i), the sheet member moving at a moving velocity greater than the circumferential velocity of the second roller in the step (ii)
Data Source
AI summary
A powder transfer roller device includes a first roller having a raised portion provided in a part of the circumferential surface of the first roller; a second roller which is opposed to the first roller and which compacts, between the second roller and the raised portion of the first roller, powder supplied between the first roller and the second roller; and a powder supplying device configured to supply powder between the first roller and the second roller.