Work

Thermal wrinkling in anode production: Defect analysis and mitigation strategies

Year: 2025

Type: article

Abstract: With the increasing demand for electric vehicles, roll-to-roll manufacturing systems have emerged as a promising approach for the large-scale and cost-effective production method of Li-ion batteries. However, this process poses unique challenges, including web wrinkle defects, referring to undesired folds, creases, or distortions that occur in the flexible, thin substrate composed of copper film during anode production. Web wrinkles can occur because of strain deviation in the cross-machining direction due to the application of nonuniform tension and the differences in geometrical and material properties. This study analyzed the thermal effects on formation of web wrinkles with respect to operating conditions (coating thickness, web speed, and web tension) and suggested guidelines for battery anode production to ensure optimal operating conditions through a series of simulations followed by experimental verification. A simulation-based analysis was performed, and a copper film and anode material were utilized for experimental verification. Excessive wrinkling was observed in cases with low coating thickness, low operating speed and high operating tension. The results indicate the effect of thermal conditions on web wrinkling and the adjustment of operating conditions required to mitigate defects such as wrinkling.

Source: Journal of Manufacturing Processes

DOI: 10.1016/j.jmapro.2025.02.069

Authors: Junyoung Yun, Yoonjae Lee, Minjae Kim, Jeongdai Jo, Changwoo Lee

Institutions: Konkuk University, Korea Institute of Machinery & Materials

Language: English

Topic: Advancements in Battery Materials

Subfield: Electrical and Electronic Engineering

Field: Engineering

Domain: Physical Sciences

SDGs: Affordable and clean energy, Industry, innovation and infrastructure

Open Access status: hybrid

Estimated APC paid: $3,520