Ultrasonic Electrode Layer Forming for High-Solid Slurry Films

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Solution Overview

Problem

Existing methods struggle to form electrode material films with low fluidity, particularly those containing 40% or more solid components, due to their high cohesive and adhesive forces, making it difficult to spread them into a film shape or layered structure.

Innovation Solution

A method and apparatus utilizing a forming member with an ultrasonic vibration applying surface, resonating at a half-wavelength of ultrasonic longitudinal vibration, to spread electrode material on a collector foil, forming a film by transporting the foil and applying ultrasonic waves to create longitudinal vibrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrode material with high solid component concentration (40% or more) is used, then the electrode material has high cohesive force and adhesive force, but it becomes extremely difficult to spread the material into a film shape or layered structure

Engineering Contradiction:

Improvecohesive forceVSAvoidfilm formation

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies ultrasonic vibration to the electrode material during the film formation process. The ultrasonic wave causes the electrode material to vibrate, reducing its cohesive force temporarily and enabling it to spread into a uniform film shape on the collector foil, thus resolving the contradiction between maintaining high cohesive force and achieving ease of film formation

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent changes the physical state parameters of the electrode material by applying ultrasonic energy. This parameter change allows the material to transition from a state with high cohesive force that resists spreading to a state where it can be easily formed into a film, while maintaining the underlying high solid component concentration

Inventive Principle:

Principle #35Parameter changes

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

Enables the formation of electrode material films with low fluidity by scattering and spreading the material on a collector foil, achieving uniform film formation with controlled thickness and cohesion.

Implementation Method 1

the forming member has an ultrasonic vibration applying surface where an ultrasonic wave is applied by an ultrasound oscillator

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

the vibration surface resonates with the ultrasonic wave applied to the ultrasonic vibration applying surface by the ultrasound oscillator

Methodology Applied

Scientific EffectResonance: Resonance

Data Source

PatentUS20260038794A1Method for manufacturing electrode layer and manufacturing apparatus for electrode layer

Publication Date: 2026.02.05 FUJIFILM CORP

AI summary

A method for manufacturing an electrode layer, including: a step A of transporting a collector foil in which an electrode material is scattered on a surface in a first direction with respect to a forming member installed at a position where a certain distance is maintained from the surface of the collector foil, to bring the forming member into contact with the electrode material.