Stepped Electrode Roll Structure for Wrinkle-Free Uncoated Edges
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Solution Overview
Problem
Existing electrode manufacturing processes face challenges in preventing wrinkles and deformation of uncoated areas during the rolling process due to differences in thickness between coated and uncoated regions, and require frequent roll replacements with changes in electrode sheet dimensions.
Innovation Solution
The introduction of a roll structure with a base surface and a step surface, where the step surface has a greater diameter than the base surface, allows for differential elongation of coated and uncoated areas, reducing wrinkles and enabling flexible adaptation to changes in electrode sheet dimensions without the need for frequent roll replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional roll with uniform surface is used for rolling the electrode sheet, then the rolling process is simple, but wrinkles and deformation occur in the uncoating area due to differential elongation between coating and uncoating regions
Solution Approach 1:
The roll surface is designed with different radii of curvature for different regions: the first surface (contacting coating area) has a first radius, while the second surface (contacting uncoating area) has a second radius. This local differentiation compensates for the thickness difference between coated and uncoated regions, preventing wrinkles and deformation in the uncoating area during rolling.
2Manufacturing precision
If a fixed roll design is used for specific electrode sheet dimensions, then rolling precision is optimized for that dimension, but frequent roll replacements are needed when electrode sheet dimensions change
Solution Approach 1:
The roll incorporates adjustable components that allow the radius of curvature to be modified based on the electrode sheet dimensions being processed. This dynamic adjustability enables the same roll to optimize rolling precision for different electrode sheet sizes without requiring frequent replacements, thereby improving both precision and adaptability.
3Productivity
If the thickness of the active material layer varies, then electrode performance can be optimized, but the roll must be replaced to accommodate different thickness variations
Solution Approach 1:
The roll design allows for adjustment of surface radius to match different active material layer thicknesses. When thickness varies, the roll parameters can be dynamically adjusted rather than replacing the entire roll, maintaining optimal rolling conditions for different electrode performances while eliminating time-consuming roll replacements.
Data Source
AI summary
An electrode manufacturing device rolls and transfers a sheet-shaped electrode in which an active material layer is applied to at least any one of a metal foil with a first surface and a second surface which is a back surface of the first surface. At least any one of a rolling roll rolling the electrode and a travel roll rolling and then transferring the electrode comprises a base roll having a predetermined diameter, and having a base surface at an outer circumference thereof; and a step ring being coupled to the outer circumference of the base roll, and having a step surface a diameter of which is greater than a diameter of the base surface. The step ring is detachably coupled to the base roll. A thickness of a step differs from a thickness of the active material layer.