Protected Electrode Coating Without Cutting-Induced Cracks

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Solution Overview

Problem

The production of electrodes with protective coatings is hindered by cracking and damage during the cutting process, which affects the performance and lifetime of electrochemical cells, as existing methods apply coatings after cutting, leading to deformation and stress on the substrate material.

Innovation Solution

A method involving cutting current collectors before applying protection layers, using a carrier system to mask regions that do not require coating, ensuring the protection layers are only applied to the electrochemically active zones, and then cutting along uncoated regions to avoid damaging the coatings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If protection layers are applied after cutting the metal foil, then the coating can be applied to the entire surface, but the cutting process causes cracks and damage to the protection layer

Engineering Contradiction:

Improveintegrity of protection layerVSAvoidcoating process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The metal foil is cut to the desired shape and size before the protection layer is applied. This preliminary cutting action prevents subsequent mechanical damage to the coating during handling and processing, as the substrate is already in its final configuration when the fragile protection layer is deposited.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The coating process is segmented into multiple steps: first applying a primer layer, then applying the main protection layer, and finally applying a top coat. This segmentation allows each layer to be optimized for its specific function while reducing overall coating stress and preventing cracking.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the entire surface is coated with protection layer, then coverage is maximized, but coating in non-active regions is wasteful and may interfere with electrode function

Engineering Contradiction:

Improveprotection coverageVSAvoidcoating material waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The protection layer is applied selectively only to the electrochemically active zones of the electrode, while non-active regions such as tabs and collection areas remain uncoated. This local quality approach ensures protection where needed while maintaining proper electrical contact and function in areas where the protection layer would be detrimental.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

A mask or carrier system is used as an intermediary during the coating process to prevent protection layer deposition on non-active regions. The mask acts as a temporary barrier that allows precise control over coating placement, ensuring material is only applied where required while facilitating easy removal after coating completion.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If roll-to-roll process is used for production, then manufacturing efficiency increases, but stretching during the process damages the protection layer

Engineering Contradiction:

Improvemanufacturing throughputVSAvoidprotection layer integrity

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

All cutting operations are completed before the protection layer is applied in the roll-to-roll process. This preliminary action ensures that the substrate is already in its final shape and size, eliminating any subsequent stretching or deformation that could damage the coating during handling, winding, or transport through the manufacturing line.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protection layer is applied with controlled thickness and appropriate material selection to provide inherent flexibility and stress resistance. This beforehand cushioning allows the coating to accommodate minor handling stresses during roll-to-roll processing without cracking, while still maintaining its protective function.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 prevents damage to the protection layers, maintaining their integrity and enhancing the performance and lifespan of electrochemical cells by ensuring even coating and reducing the risk of short-circuiting and dendrite formation.

Implementation Method 1

preventing degradation associated with such electrodes may be advantageous. This may be achieved by the application of one or more protection layers on the surface of an electrode

Methodology Applied

Scientific EffectPhysical barrier protection:

Implementation Method 2

applying one or more protection layers to one or both sides of the current collector to form a coated electrode

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS12166193B2Electrode production process

Publication Date: 2024.12.10 GELION TECH PTY LTD

AI summary

A method for forming at least one electrode, said method comprising: a) providing an electronically conductive, inert material; b) cutting the substrate material to form at least one current collector; c) placing at least one current collector on a carrier; d) applying one or more protection layers to one or both sides of the current collector to form a coated electrode; and e) removing the electrode from the carrier.