Sheet Electrode Coating Blade for Uniform Semi-Solid Film Thickness
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Solution Overview
Problem
The manufacturing of molded bodies for sheet-like electrodes in semi-solid state batteries or all-solid state batteries faces challenges in achieving excellent in-plane thickness uniformity, especially when using electrode materials with low electrolytic solution content.
Innovation Solution
A manufacturing method involving the formation of an electrode material film on a support using an electrode material with a high concentration of solid components. This method employs a blade with a specific shape, where both end parts protrude more than the center portion in the width direction, and the center portion vibrates, to regulate the thickness and width of the electrode material film effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrode material with low electrolytic solution content is used, then the electrode material can be applied onto the support, but the thickness of the electrode material film varies and excellent in-plane thickness uniformity cannot be obtained
Solution Approach 1:
The blade performs ultrasonic vibration at a frequency of 20 kHz to 100 kHz in the width direction during the coating process. This mechanical vibration prevents the electrode material from adhering to the blade and ensures uniform thickness distribution across the film, directly resolving the thickness uniformity problem when using electrode materials with low electrolytic solution content.
Solution Approach 2:
The invention changes the operating parameters of the blade, specifically setting the vibration frequency to 20 kHz to 100 kHz and maintaining a specific gap distance of 0.01 mm to 1 mm from the support surface. These parameter adjustments enable effective thickness control and uniformity achievement during the coating process.
2Manufacturing precision
If a blade with protruding end parts and vibrating center portion is used, then the thickness and width of the electrode material film can be regulated effectively, but the device complexity increases
Solution Approach 1:
The blade integrates multiple functions into a single component: it serves as both the coating applicator and the thickness regulator, while also functioning as a width definer through its protruding end parts. The vibration mechanism is incorporated directly into the blade structure, merging what could be separate systems into one integrated tool.
Solution Approach 2:
The blade is designed to perform multiple functions simultaneously: coating the electrode material, regulating film thickness through the gap distance, controlling film width through protruding end parts, and ensuring uniform distribution through ultrasonic vibration. This multi-functionality reduces the need for additional separate components.
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 achieves a molded body for a sheet-like electrode with excellent in-plane thickness uniformity, enhancing the manufacturing efficiency and quality of electrodes for batteries.
Implementation Method 1
the center portion in the width direction vibrates, along the surface of the support such that a thickness is regulated by a void between the surface of the support and the center portion of the blade
Data Source
AI summary
Provided is a manufacturing method of a molded body for a sheet-like electrode, the manufacturing method including a step of forming an electrode material film on a support using an electrode material which contains an electrode active material and has a concentration of solid components of 30% by volume or more, in which, with the electrode material supplied onto the support, the electrode material film is formed by, while maintaining a constant distance from a surface of the support, relatively moving a blade having a shape in which both end parts in a width direction protrude than a center portion in the width direction and the center portion in the width direction vibrates, along the surface of the support such that a thickness is regulated by a void between the surface of the support and the center portion of the blade in the width direction and a width is regulated by both end parts of the blade in the width direction, which protrude than the center portion of the blade in the width direction.