Squeegee Roll Layout for Uniform Electrode Particle Layers

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Solution Overview

Problem

Existing production apparatuses for electrode active material layers face issues with granulated particles being wasted and the quality of the layer deteriorating due to excess particles being conveyed downstream, leading to defects in the rolling unit and uneven layer formation.

Innovation Solution

A production apparatus with a squeegee device featuring cylindrical rolls, stock guides, and a rotation shaft, where the stock guides and squeegee rolls are alternately disposed, and the rotation shaft is freely rotatable, allowing for precise control of the granulated particle layer formation to prevent excess particles from being wasted and ensure stable belt-like non-forming portions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a squeegee device levels and guides granulated particles to both widthwise end portions, then the thickness uniformity of the granulated particle layer is improved, but excess granulated particles may be conveyed downstream causing defects in the rolling unit and electrode active material layer

Engineering Contradiction:

Improvethickness uniformity of granulated particle layerVSAvoiddefect-free formation of electrode active material layer

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent extracts the problematic excess granulated particles from the system by introducing a removal device that actively removes particles from both widthwise end portions of the granulated particle layer. This prevents the particles from being conveyed downstream to the rolling unit, thereby resolving the contradiction between achieving uniform thickness and preventing downstream defects.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a removal device as an intermediary component between the squeegee device and the rolling unit. This intermediary device captures and removes excess granulated particles before they can cause defects in the rolling unit or the electrode active material layer, while preserving the beneficial thickness-uniformizing effect of the squeegee device.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If guide members are used to form areas where granulated particles are not deposited, then belt-like non-forming portions can be created, but the guide members may deviate from the original installation position due to vibration causing uneven layer formation

Engineering Contradiction:

Improveformation of belt-like non-forming portionsVSAvoidposition stability of guide members

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies the dynamics principle by making the guide members movable rather than fixed. The guide members are designed to be movable in the widthwise direction and are positioned by a positioning device, allowing them to adapt to vibrations and maintain their functional position. This resolves the contradiction between ease of manufacture and position stability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The guide members are designed to self-adjust to vibrations through their movable configuration. The positioning device enables the guide members to automatically compensate for positional deviations caused by vibrations, eliminating the need for complex rigid fixation systems and maintaining manufacturing precision.

Inventive Principle:

Principle #25Self-service

3Quantity of substance

If granulated particles are fed in excessive amounts to ensure adequate layer coverage, then the granulated particle layer can be fully formed, but excess particles are conveyed downstream causing waste and quality deterioration

Engineering Contradiction:

Improveadequate coverage of granulated particle layerVSAvoidwaste of granulated particles

Core Design Contradiction:

Quantity of substanceVSLoss of substance

Solution Approach 1:

The patent converts the harmful effect of excess granulated particles into a beneficial outcome by introducing a removal device that actively removes these particles. The removal device transforms the waste problem into an opportunity to improve both material utilization and product quality, as it selectively removes only the excess particles that would otherwise be wasted while preserving the adequately formed layer.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS20250023010A1Apparatus for manufacturing electrode active material layer

Publication Date: 2025.01.16 ZEON CORP

AI summary

A production apparatus of an electrode active material layer, comprising: a support unit; a feeding unit feeding prescribed granulated particles on or above the support unit; a first conveying unit; a squeegee device; and a rolling unit. The squeegee device includes a cylindrical squeegee roll, stock guides being in a plate shape and having a shaft hole, a rotation shaft inserted into the stock guide and penetrating the squeegee roll in an axial direction of the squeegee roll, and a fixing member restricting movement of the stock guides in an axial direction of the rotation shaft. The stock guides and the squeegee roll are alternately disposed along the axial direction of the rotation shaft. The stock guides are disposed at both ends of the squeegee roll in the axial direction. The squeegee roll is fixed to the rotation shaft. The rotation shaft is freely rotatable to the stock guides.