Mechanical Sacrificial Layer Stripping for Wrinkle-Free Calendering
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Solution Overview
Problem
Calendering processes in energy storage device manufacturing often result in wrinkles due to non-uniform thickness or compressibility of electrode coatings, leading to reduced performance and manufacturing issues.
Innovation Solution
Applying a sacrificial material with similar compressibility to uncoated areas of the foil during calendering, followed by its removal using methods like laser ablation, vacuum capture, or dry etching to ensure uniform pressure and minimize surface deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the entire foil is coated with active material to ensure uniform pressure during calendering, then wrinkles are reduced, but manufacturing cost increases due to expensive active material usage
Solution Approach 1:
The patent introduces a sacrificial layer as an intermediary material coated on portions of the foil where active material is not applied. This sacrificial layer has similar compressibility to the active material, allowing it to serve as a placeholder that maintains uniform pressure distribution during calendering. After calendering, the sacrificial layer is removed, having fulfilled its temporary function of preventing wrinkles without consuming expensive active material.
Solution Approach 2:
The patent applies the sacrificial layer selectively to specific portions of the foil where active material is not coated, rather than coating the entire foil with active material. This local application of sacrificial material provides the necessary compressibility matching only where needed, reducing overall material consumption while still achieving uniform pressure distribution during the calendering process.
2Productivity
If calendering is performed on objects with non-uniform thickness or compressibility, then manufacturing efficiency is maintained, but wrinkles are created that reduce device performance
Solution Approach 1:
The patent modifies the compressibility parameter of the foil structure by adding the sacrificial layer to areas without active material. This changes the local compressibility parameter to match areas with active material, ensuring that during calendering, both regions compress uniformly. This parameter matching allows the calendering process to proceed efficiently without creating wrinkles, thus maintaining both productivity and surface uniformity.
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
The method reduces wrinkles and ensures even pressure during calendering, maintaining electrode integrity and performance while minimizing alternate material on the active material surface.
Implementation Method 1
The sacrificial layer may be removed using laser ablation
Implementation Method 2
some of the alternate material particles may deposit on the surface of the active material
Data Source
AI summary
Systems and methods are provided herein for removing alternate material from a foil while minimizing the amount of alternate material particles that are deposited on the surface of an active material. For example, a web may comprise an active material on a first portion of a foil and an alternate material on a second portion of the foil. One or more brushes may be used to remove the alternate material from the second portion of the foil. As the one or more brushes remove the alternate material from the second portion of the foil, a vacuum may be used to capture the alternate material that is removed from the second portion of the foil. In such an example, the resulting web no longer has alternate material on the second portion of the foil and has reduced alternate material particles on the surface of the active material.