Undercoat Foil Ultrasonic Welding via Thickness Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current energy storage devices face challenges in achieving efficient ultrasonic welding of undercoat layers, leading to higher resistance and reduced productivity, especially when using carbon materials, which affects the versatility and safety of electrical storage devices.
Innovation Solution
The undercoat layer for energy storage device electrodes is formed with a thickness of 1 to 200 nm, incorporating carbon nanotubes and a dispersant, enabling efficient ultrasonic welding and reducing resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the undercoat layer thickness is increased to improve adhesion and lower contact resistance, then the welding quality deteriorates due to inability to achieve reproducible ultrasonic welding
Solution Approach 1:
The patent applies parameter changes by precisely controlling the undercoat layer thickness within the range of 1-200 nm. This specific thickness parameter enables both good adhesion strength and reproducible ultrasonic welding quality, resolving the contradiction between reliability and ease of manufacture.
Solution Approach 2:
The patent uses composite materials by combining carbon nanotubes with a dispersant to form the undercoat layer. This composite structure provides both the adhesion benefits of carbon nanotubes and the welding compatibility enabled by the dispersant, achieving both reliability and manufacturability.
2Ease of manufacture
If the undercoat layer is stripped off to enable welding, then welding can be performed, but device productivity decreases due to additional processing steps
Solution Approach 1:
The patent changes the thickness parameter of the undercoat layer to 1-200 nm, which is thin enough to allow ultrasonic welding to penetrate and bond effectively without requiring removal of the undercoat layer. This eliminates the additional stripping step and maintains high device productivity.
3Ease of manufacture
If the undercoat layer is not formed at the welding region to enable welding, then welding can be performed, but current-collecting substrate versatility decreases
Solution Approach 1:
The patent applies asymmetry by creating different functional zones within the undercoat layer: the welding region has sufficient thickness (1-200 nm) for good ultrasonic welding, while other regions maintain the full undercoat layer for optimal adhesion and electrical contact. This asymmetric thickness distribution enables both welding capability and substrate versatility.
Solution Approach 2:
The patent implements local quality by optimizing the undercoat layer thickness specifically at the welding region to enable ultrasonic welding, while maintaining the undercoat layer elsewhere for adhesion and contact resistance benefits. This localized optimization achieves welding capability without sacrificing overall substrate versatility.
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
This approach allows for the production of low-resistance energy storage devices with improved weldability and productivity, specifically enhancing the performance of lithium-ion secondary batteries and electrical double-layer capacitors.
Implementation Method 1
efficient ultrasonic welding
Implementation Method 2
lowering the resistance at the contact interface
Data Source
AI summary
This undercoat layer for an energy storage device has a thickness of 1-200 nm. An undercoat foil provided with the undercoat layer is capable of being ultrasonically welded efficiently. An energy storage device exhibiting low resistance can be obtained by using an electrode provided with the undercoat foil.