Scholarlink

<p>The trend toward ultrathin aluminum foil collectors (5–20&#xa0;<i>µ</i>m) in supercapacitors introduces wrinkling in blank areas during roll-to-roll calendering as a critical manufacturing defect. These wrinkles compromise electrode structural integrity, which may adversely affect subsequent manufacturing processes such as tab welding and winding. This study investigates this failure mechanism by developing an analytical wrinkling model for the foil’s blank area based on membrane theory. The model analyzes stress states under unilateral and bilateral calendering pressure, establishing wrinkle formation criteria. Finite element simulations further quantify the influence of key process parameters, and the results demonstrate that tension and calendering pressure are predominant factors controlling wrinkle severity. Strategic optimization of these parameters, alongside the application of edge pre-displacement, effectively suppresses wrinkling. This mitigation enhances electrode flatness, which is directly linked to improved interfacial contact and electrochemical performance stability. The work provides a fundamental failure analysis and practical guidance for enhancing electrode manufacturing reliability.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Analysis and Mitigation of Wrinkling Failure in Ultrathin Aluminum Foil Collectors During Calendering of Supercapacitor Electrodes

  • 期刊论文

  • 发表日期：

    2026年8月4日

查看全文
  • Jianfei Tu,
  • Yang Lv,
  • Zhijun Qiao,
  • Guoping Li

摘要

The trend toward ultrathin aluminum foil collectors (5–20 µm) in supercapacitors introduces wrinkling in blank areas during roll-to-roll calendering as a critical manufacturing defect. These wrinkles compromise electrode structural integrity, which may adversely affect subsequent manufacturing processes such as tab welding and winding. This study investigates this failure mechanism by developing an analytical wrinkling model for the foil’s blank area based on membrane theory. The model analyzes stress states under unilateral and bilateral calendering pressure, establishing wrinkle formation criteria. Finite element simulations further quantify the influence of key process parameters, and the results demonstrate that tension and calendering pressure are predominant factors controlling wrinkle severity. Strategic optimization of these parameters, alongside the application of edge pre-displacement, effectively suppresses wrinkling. This mitigation enhances electrode flatness, which is directly linked to improved interfacial contact and electrochemical performance stability. The work provides a fundamental failure analysis and practical guidance for enhancing electrode manufacturing reliability.