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The manufacturing of lithium-ion batteries (LIB) includes a series of steps, of which calendering is a crucial one which could significantly influence subsequent ones and the overall battery performance. Currently, a large roll force is required in the calendering process to increase the volumetric energy density of the electrode. However, considerable stress may cause corrugations and wrinkles in the electrode due to the differences in elongation between the current collector foil and active material coating region, which increase rejection rates and lower production efficiency. Addressing these defects, particularly wrinkles, remains challenging nowadays in the lithium-ion battery industry. This paper proposes a pre-calendering processing method for the current collector region, which could significantly reduce corrugations and wrinkles and improve the morphology of electrodes. Experiments were carried out to analyze several process parameters, namely rolling speed, calendering pressure and front and back tensions to investigate their influence both on the pre-calendering process and the final morphology of the electrodes. A 3D laser scanning system was employed to measure the extension rate after pre-calendering and the curvature of the calendered electrode. It is found that higher rolling speed and pressure resulted in larger current collector elongation during the pre-calendering step, while lower rolling speeds, higher pressure and larger front and back tensions lead to better elimination of corrugations as well as better morphology performances of the electrode. To analyze the effectiveness of pre-extension and final quality, elongation and deflection rate were defined and measured. It turns out when the elongation of current-collector region exceeds the elongation of the coated region, larger elongation suggests higher deflection rate and worse morphology quality. The methodology presented in this paper contributes to eliminate LIB electrode defects, thereby reducing rejection rate and enhancing production quality.

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Elimination of Lithium-Ion Battery Electrode Corrugation and Wrinkles Based on Pre-extension During Calendering Process

  • 会议论文

  • 发表日期：

    2025年

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  • Zhilin Deng,
  • Huanyang Lv,
  • Zejun Fu,
  • Ziyang Ding,
  • Haitong Luo,
  • Tianyu Zhang,
  • Zhutian Xu,
  • Linfa Peng

摘要

The manufacturing of lithium-ion batteries (LIB) includes a series of steps, of which calendering is a crucial one which could significantly influence subsequent ones and the overall battery performance. Currently, a large roll force is required in the calendering process to increase the volumetric energy density of the electrode. However, considerable stress may cause corrugations and wrinkles in the electrode due to the differences in elongation between the current collector foil and active material coating region, which increase rejection rates and lower production efficiency. Addressing these defects, particularly wrinkles, remains challenging nowadays in the lithium-ion battery industry. This paper proposes a pre-calendering processing method for the current collector region, which could significantly reduce corrugations and wrinkles and improve the morphology of electrodes. Experiments were carried out to analyze several process parameters, namely rolling speed, calendering pressure and front and back tensions to investigate their influence both on the pre-calendering process and the final morphology of the electrodes. A 3D laser scanning system was employed to measure the extension rate after pre-calendering and the curvature of the calendered electrode. It is found that higher rolling speed and pressure resulted in larger current collector elongation during the pre-calendering step, while lower rolling speeds, higher pressure and larger front and back tensions lead to better elimination of corrugations as well as better morphology performances of the electrode. To analyze the effectiveness of pre-extension and final quality, elongation and deflection rate were defined and measured. It turns out when the elongation of current-collector region exceeds the elongation of the coated region, larger elongation suggests higher deflection rate and worse morphology quality. The methodology presented in this paper contributes to eliminate LIB electrode defects, thereby reducing rejection rate and enhancing production quality.