Coating surface density regulation and control method and closed-loop system

Abstract

The invention provides a coating surface density regulation and control method and a closed-loop system.The closed-loop system comprises a die head for coating, an upper die cavity is formed in a middle die of the die head, an upper gasket comprises an opening area, and a micro motor and a flow choking block are arranged on an upper die. The method comprises the following steps that a coating area is partitioned based on the opening area of the upper gasket to form a plurality of sub-areas; grouping the flow choking blocks above according to the sub-regions of the coating region; performing slurry coating on the base material by using a die head, and acquiring surface density detection data after coating in real time; and analyzing the surface density detection data to obtain an abnormal analysis result, and performing stroke adjustment on the choked flow blocks based on the abnormal analysis result and the grouping result of the choked flow blocks so as to adjust the coating surface density of the base material. In the lithium battery coating production and manufacturing process, manual control is not needed, the area with the abnormal surface density is automatically adjusted, the scrap amount is greatly reduced, the production cost is reduced, and the product competitiveness is improved.

Description

Technical Field

[0001] The present invention relates to the field of lithium battery manufacturing technology and coating technology, and in particular to a coating surface density control method and a closed-loop system. Background Art

[0002] With the development of the new energy industry, lithium batteries are widely used in various industries, from commercial aerospace, power batteries, and photovoltaic energy storage to electric bicycles, home appliances, and mobile phone batteries. Competition among major manufacturers is becoming increasingly fierce. In order to compete for market share and improve market competitiveness, they need to continuously reduce the cost of lithium battery manufacturing.

[0003] The coating process, a key step in lithium battery manufacturing, involves spraying the slurry onto the surface of the substrate through a die, drying it, and then winding it into a coil. Wide-width pole pieces are typically coated in a one-out-two or one-out-four pattern, while narrow-width pole pieces are typically coated in a one-out-four or one-out-eight pattern. Therefore, any abnormal density data at any stage in the manufacturing process will result in a large number of scrapped products. The time required from discovering the abnormal density to manually resolving it inevitably results in significant losses. Summary of the Invention

[0004] The present invention provides a coating surface density control method and a closed-loop system, aiming to solve technical problems such as high scrap rate in the coating link in lithium battery manufacturing in the prior art.

[0005] A method for controlling coating surface density includes a coating die head, wherein the die head comprises an upper die, an upper gasket, and a middle die from top to bottom, wherein the middle die is provided with an upper die cavity, the upper gasket includes an opening area, and the upper die is provided with a plurality of flow blocks facing the upper die cavity, each flow block being connected to a micro motor, and comprising the following steps:

[0006] Step A1, partitioning the coating area into a plurality of sub-areas based on the opening area of ​​the upper gasket;

[0007] Step A2, grouping the upper flow blocks according to the sub-areas of the coating area to obtain a grouping result of the flow blocks;

[0008] Step A3, coating the substrate with the slurry using a die head, and obtaining surface density detection data after coating in real time;

[0009] Step A4: Analyze the surface density detection data to obtain an abnormality analysis result, determine the baffle to be adjusted based on the abnormality analysis result and the baffle grouping result, and adjust the stroke of the baffle to be adjusted to adjust the coating surface density of the substrate.

[0010] Furthermore, in step A1, the coating area is divided into sub-regions according to the main coating area, the thinning area, and the blank area. The dividing line between two adjacent sub-regions forms a critical area, the dividing line between the main coating area and the thinning area is used as the first critical area, and the dividing line between the thinning area and the blank area is used as the second critical area.

[0011] In step A2, the flow blocks are grouped into flow blocks in the main coating area, flow blocks in the thinning area, and flow blocks in the blank area, and the flow blocks in the first critical area and the flow blocks in the second critical area are marked to obtain the grouping result of the flow blocks;

[0012] In step A2, a priority adjustment strategy of the blocking block is also defined according to the grouping result of the blocking block;

[0013] In step A4, the corresponding regulating block is adjusted based on the abnormality analysis result, the grouping result of the block, and the priority regulation strategy of the block, so as to adjust the coating surface density of the substrate.

[0014] Furthermore, the priority adjustment strategy includes a first adjustment priority strategy and a second adjustment priority strategy;

[0015] In the first regulation priority strategy, the flow block corresponding to the area with abnormal surface density has the highest regulation priority;

[0016] In the second adjustment priority strategy, the flow blocks are adjusted in the following priority adjustment order: the flow blocks in the main coating area, the flow blocks in the first critical area, the flow blocks in the thinning area, the flow blocks in the second critical area, and the flow blocks in the blank area;

[0017] In step A4, the first adjustment strategy and the second adjustment priority strategy are selected and used based on the number, distribution, area and surface density value of the surface density abnormality regions in the abnormality analysis results.

[0018] Furthermore, in step A4, after selecting to use the first adjustment priority strategy to preferentially adjust the flow blocking blocks corresponding to the surface density abnormality areas in the abnormality analysis results, the following steps are further performed:

[0019] Step B1: Determine whether the abnormality analysis result corresponding to the real-time acquired surface density detection data meets the preset surface density standard:

[0020] If so, end the use of the first adjustment priority strategy;

[0021] If not, go to step B2;

[0022] Step B2: Select and use the second adjustment priority strategy to adjust the choke.

[0023] Furthermore, in step A4, the maximum adjustment stroke of the baffle blocks in the thinning area and the first critical area is calculated as follows:

[0024]

[0025] Wherein, Y represents the maximum adjustment stroke of the flow block in the thinning area / first critical area, m represents a constant value, and X represents the maximum adjustment stroke of the main coating area;

[0026] In step A4, the calculation formula for the maximum adjustment stroke of the baffle block in the blank area and the second critical area is expressed as follows:

[0027] Z=Y+n

[0028] Wherein, Z represents the maximum adjustment stroke of the baffle block in the blank area / second critical area, and n is the standard coating thickness of the thinning area.

[0029] Furthermore, in step A2, the grouping result of the flow blocks includes the flow blocks of each sub-region and the flow blocks of the critical area of ​​two adjacent sub-regions;

[0030] Step A4 includes: when the baffles to be adjusted include baffles in the critical area associated with the sub-area with the abnormal area density in the abnormality analysis result, executing the following steps:

[0031] Step A41: Determine the ratio of the local area of ​​the baffle block in the critical area to be adjusted, which faces the sub-region where the surface density anomaly exists, to the total area of ​​the baffle block:

[0032] If it is not less than the first threshold, execute step A42;

[0033] If it is less than the first threshold, execute step A43;

[0034] Step A42, adjusting the baffle block by taking a predetermined unit adjustment stroke as the unit adjustment stroke of the baffle block in the critical area to be adjusted;

[0035] In step A43, the flow block is adjusted by assigning a weight to the predetermined unit adjustment stroke as the unit adjustment stroke of the flow block in the critical area to be adjusted. The calculation formula is as follows:

[0036] H(adjacent)=H×(S1 / S2)

[0037] in,

[0038] H (adjacent) represents the unit adjustment stroke of the baffle in the critical area to be adjusted;

[0039] H indicates the preset unit adjustment stroke;

[0040] S1 represents the local area of ​​the sub-region where the surface density anomaly exists and the baffle block of the critical region to be adjusted faces;

[0041] S2 represents the local area of ​​the baffle in the critical region to be adjusted facing the sub-region adjacent to the sub-region where the surface density anomaly region exists.

[0042] A coating closed-loop system for executing the aforementioned coating surface density control method comprises:

[0043] An unwinding component, used for unwinding the substrate to be coated;

[0044] The spray assembly is used to spray the slurry onto the substrate, including a die head. The die head comprises an upper die, an upper gasket and a middle die from top to bottom. The middle die is provided with an upper die cavity. The upper gasket includes an opening area. The upper die is provided with a plurality of flow blocks facing the upper die cavity. Each flow block is connected to a micro motor.

[0045] An oven assembly, used for drying the slurry sprayed onto the substrate;

[0046] A detection component is used to perform real-time detection on the substrate after drying to obtain surface density detection data;

[0047] A winding component is used to wind up the coated substrate;

[0048] The host computer is connected to the detection component and the spray component respectively, and is used to:

[0049] Recording the coating area of ​​the die head and the sub-areas formed by the area, as well as the grouping results of the flow blocks obtained according to the sub-areas;

[0050] Acquire area density detection data from the detection component, and analyze the area density detection data to obtain an abnormality analysis result;

[0051] Determine the flow block to be adjusted based on the abnormality analysis result and the grouping result of the flow blocks, generate the flow block adjustment parameters, and send the flow block adjustment parameters to the spray assembly;

[0052] The spray assembly is used to drive the micro motor of the die head to adjust the stroke of the baffle block based on the baffle block adjustment parameters, so as to adjust the coating surface density of the substrate.

[0053] Further, the upper gasket includes an outer solid area and at least one inner solid area;

[0054] The lateral solid area includes the left solid area, the right solid area and the dorsal solid area, and the left solid area, the right solid area and the medial solid area are connected to the dorsal solid area;

[0055] A first notch is formed on the inner side of the left solid area and the inner side of the right solid area, which passes through the first notch vertically;

[0056] The inner solid area is provided with a second notch facing the upper mold and not penetrating vertically.

[0057] Furthermore, the die head also includes a lower die and a lower gasket, the lower gasket is arranged between the lower die and the middle die, and the lower die is provided with a lower die cavity facing the middle die.

[0058] Furthermore, the coating closed-loop system is a double-sided coating system, and also includes a back-roll assembly and a pass-roll assembly;

[0059] The roller assembly includes a first group of rollers and a second group of rollers, the back roller assembly includes a first back roller and a second back roller, the oven assembly includes a first oven and a second oven, and the detection assembly includes a first surface density detector and a second surface density detector;

[0060] The spraying assembly includes a first coater and a second coater, and both the first coater and the second coater include a die head;

[0061] The first group of rollers transfers the substrate unwound by the unwinding assembly to the first backing roller, the first coater sprays the slurry on the first surface of the substrate at the first backing roller, and the first backing roller transfers the substrate to the first oven;

[0062] The first surface density detector performs surface density detection on the first surface of the substrate that has been dried in the first oven to obtain surface density detection data of the first surface of the substrate;

[0063] The second group of rollers transfers the substrate dried in the first oven to the second back roller, the second coater sprays the slurry on the second surface of the substrate at the second back roller, and the second back roller transfers the substrate to the second oven;

[0064] The second surface density detector performs surface density detection on the first surface and the second surface of the substrate dried in the second oven to obtain surface density detection data of both surfaces of the substrate.

[0065] The beneficial technical effect of the present invention is that the present invention partitions the opening area, groups the baffles according to the partitions, and adjusts the baffles in real time based on the analysis results of the surface density detection data. This allows for automatic adjustment of areas with abnormal surface density during the lithium battery coating and manufacturing process without the need for manual control, thereby greatly reducing the amount of scrap, lowering production costs, and improving product competitiveness. BRIEF DESCRIPTION OF THE DRAWINGS

[0066] Figure 1 This is a schematic structural diagram of a coating closed-loop system of the present invention;

[0067] Figure 2 A schematic diagram of a coating surface density control method and a die head in a closed-loop system of the present invention;

[0068] Figure 3 A schematic diagram of the structure of a coating surface density control method and an upper gasket of a die head in a closed-loop system of the present invention;

[0069] Figure 4 It is a structural schematic diagram of a coating surface density control method and an upper die belt flow-blocking component in a closed-loop system of the present invention;

[0070] Figure 5-Figure 6 This is a schematic diagram of the coating area of ​​the upper gasket of the present invention;

[0071] Figure 7 This is a diagram showing an example of the local area of ​​the flow blocking block in each sub-region of the critical area of ​​the present invention;

[0072] Figure 8-10 The present invention is a flowchart of the steps of a method for controlling coating surface density.

[0073] in,

[0074] 1- unwinding assembly; 11- unwinding substrate; 12- unwinding bracket;

[0075] 2-spraying assembly; 21-first coating machine; 22-second coating machine;

[0076] 3-back roller assembly; 31-first back roller; 32-second back roller;

[0077] 4- roller assembly; 41- first roller; 42- second roller; 43- third roller; 44- fourth roller; 45- fifth roller; 46- sixth roller;

[0078] 5- oven assembly; 51- second oven; 52- first oven;

[0079] 6- detection component; 61- second surface density detector; 62- second surface density detector;

[0080] 7-winding assembly; 71-winding bracket; 72-winding pole piece;

[0081] 8- Host computer;

[0082] a-upper die; b-middle die; c-lower die; d-upper gasket; e-lower gasket; f-upper die cavity; g-lower die cavity; h-upper die lip; i-lower die lip; j-blocking component;

[0083] d1-opening area; d2-outer solid area; d3-inner solid area;

[0084] A-main coating area; B-thinning area;

[0085] d21-left solid area; d22-right solid area; d23-dorsal solid area;

[0086] d211-the first notch of the left entity area, d221-the first notch of the right entity area;

[0087] d31-second notch;

[0088] j1-limit ladder; j2-micro motor; j3-execution block; j31-end handle; j32-T block. DETAILED DESCRIPTION

[0089] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0090] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.

[0091] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but they are not intended to limit the present invention.

[0092] See also Figures 2 to 8 The present invention provides a coating surface density control method, comprising a coating die head, wherein the die head comprises, from top to bottom, an upper die a, an upper gasket d, and a middle die b, wherein the middle die b is provided with an upper die cavity f, the upper gasket d includes an opening area d1, and the upper die a is provided with a plurality of flow blocks j32 facing the upper die cavity f, each flow block j32 being connected to a micro motor j2, comprising the following steps:

[0093] Step A1, partitioning the coating area into multiple sub-areas based on the opening area d1 of the upper gasket d;

[0094] Step A2, grouping the upper baffle j32 according to the sub-areas of the coating area to obtain the grouping results of the baffle j32;

[0095] Step A3, coating the substrate with the slurry using a die head, and obtaining surface density detection data after coating in real time;

[0096] Step A4: Analyze the surface density detection data to obtain an abnormality analysis result, determine the baffle j32 to be adjusted based on the abnormality analysis result and the grouping result of the baffle j32, and adjust the stroke of the baffle j32 to adjust the coating surface density of the substrate.

[0097] refer to Figure 2Specifically, the die head of the coating machine can be a single-layer die head formed by the flow blocking component j, the upper die a, the upper gasket d, the middle die b, the upper die cavity f, and the upper die lip h, or a double-layer die head formed by the upper die a, the middle die b, the lower die c, the upper gasket d, the lower gasket e, the upper die cavity f, the lower die cavity g, the upper die lip h, the lower die lip i, and the flow blocking component j. The die head of the coating machine is mainly used to control the spraying effect of the slurry. The single-layer die head and the middle die can be used for spraying, or only the upper layer of the double-layer die head, i.e., the upper die and the middle die, can be used for spraying.

[0098] The main design of the upper gasket d and the lower gasket e is the same, the difference is that the upper gasket d has an adjustment for the baffle j32 relative to the lower gasket e, and the design is more complicated. Figure 3 As shown, the upper gasket d includes an opening area d1, an outer solid area d2, and an inner solid area d3. The opening area d1 is composed of multiple single-zone blank sections, which can be one, two, or three. Each single-zone blank section includes a main coating area (area A) and two skived areas (areas B). Within a single-zone blank section, the two skived areas (areas B) are distributed on both sides of a main coating area (area A).

[0099] The outer solid area d2, comprising a left solid area d21, a right solid area d22, and a back solid area d23, primarily serves to seal the outer areas of the upper mold a and the middle mold b. Its outer contours correspond to the outer contours of the bottom of the upper mold a and the top of the middle mold b. Specifically, the left and right solid areas d21 and d22 of the upper gasket d each contain a first notch d211 and d221 extending vertically through them, located near the opening d1. These notches prevent overloading of the micromotor j2 caused by the internal baffle j32 being stuck outside the opening d1. These first notches correspond to the upper mold cavity f below.

[0100] The inner solid area d3 is located between any two single-zone blank sections. Multiple inner solid areas d3 can exist, ranging from 0, 1, to 2. If the opening area only has a single blank section, then the inner solid area d3 does not exist. Specifically, the inner solid area d3 of the upper gasket d has a second notch d31, which does not extend vertically through the inner solid area d3, at a position corresponding to the vertical travel of the baffle j32. This notch d31 serves to buffer the baffle j32's travel, preventing overload on the baffle j32's micromotor j2 and forming a blank space for the tab.

[0101] Specifically, the upper die cavity f is a semicircular inner cavity. The upper die lip h is formed by the upper die a, the middle die b, and the slit of the upper gasket d near the discharge side. The upper die cavity f is used to buffer the slurry sprayed on the upper layer, and the upper die lip h is used to shape and spray the slurry.

[0102] Specifically, the lower die cavity g is a semicircular inner cavity. The lower die lip i is formed by the lower die c, the middle die b, and the slit of the lower gasket e near the discharge side. The lower die cavity g is used to buffer the slurry sprayed on the lower layer, and the lower die lip i is used to shape and spray the slurry.

[0103] choke components such as Figure 4 As shown, it includes a limit ladder j1, a micro motor j2, and an actuator j3. The actuator j3 includes an end handle j31 and a flow block j32. It is located in the middle of the upper mold a, and its up and down adjustment range is directly opposite the upper mold cavity f. Multiple identical flow block j32 units are used to adjust the surface density.

[0104] The limiting ladder j1 is in a Z-shaped step shape, one end of which is fixedly connected to the surface of the upper mold a, and the other end is used to fix the position of the micro motor j2 to ensure that the micro motor j2 does not deviate during movement.

[0105] The actuator j3 consists of a handle j31 and a choke j32. The handle j31's top is threadedly connected to the output shaft of the micromotor j2, while its bottom is integrally connected to the choke j32, ensuring linear adjustment. After the micromotor j2 returns to zero, the bottom surface of the choke j32 is flush with the bottom surface of the upper mold a.

[0106] Specifically, the baffle j32 is a T-block. The present invention partitions the opening area, groups the baffles according to the partitions, and adjusts the baffles in real time based on the analysis results of the surface density test data. This allows for automatic adjustment of areas with abnormal surface density during the lithium battery coating and manufacturing process without manual control, significantly reducing scrap, lowering production costs, and improving product competitiveness.

[0107] like Figure 3 、 Figure 5-7 As shown, further, in step A1, the coating area is divided into sub-areas according to the main coating area (area A), the thinning area (area B) and the blank area (area C), and the dividing line between two adjacent sub-areas forms a critical area, the dividing line between the main coating area (area A) and the thinning area (area BA) serves as the first critical area (area AB), and the dividing line between the thinning area (area B) and the blank area (area C) serves as the second critical area (area BC);

[0108] In step A2, the baffles j32 are grouped into baffle group A in the main coating area (area A), baffle group B in the thinning area (area B), and baffle group C in the blank area (area C). The baffle group AB in the first critical area and the baffle group BC in the second critical area are marked to obtain the grouping result of the baffle j32.

[0109] In step A2, a priority adjustment strategy of the blocking block j32 is also defined according to the grouping result of the blocking block j32;

[0110] In step A4, the corresponding baffle j32 is adjusted based on the abnormality analysis result, the grouping result of the baffle j32, and the priority adjustment strategy of the baffle j32 to adjust the coating surface density of the substrate.

[0111] In step A1, determine the number of coating areas and divide the coating areas into sub-areas. Determine the number of coating areas according to the number of upper gasket opening areas, and the number of coating areas ≥ 1. Determine the coating width by the parameters of the single-area blank part of the upper gasket d opening area d1. According to the actual process requirements, the single-area blank part is divided into the main coating area (area A) and the thinning area (area B). Determine the blank area according to the width of the left solid area d21, the right solid area d22 and the inner solid area d3 of the upper gasket d and the substrate 11. The blank area is called area C, as shown in FIG. Figure 4-Figure 5 shown.

[0112] In step A2, if Figure 5 As shown, the baffles above the main coating area (area A) are defined as the baffle group A of the main coating area, which consists of a plurality of baffles A1, A2...An, and the value of n is determined by the specific number. The baffles above the thinning area (area B) are defined as the baffle group B of the thinning area, which consists of a plurality of baffles B1, B2...Bn, and the value of n is determined by the specific number. The baffles above the blank area (area C) are defined as the baffle group C of the blank area, which consists of a plurality of baffles C1, C2...Cn, and the value of n is determined by the specific number.

[0113] As a preferred embodiment of the present invention, the upper baffle corresponding to the area with abnormal density is adjusted based on the abnormality analysis results and the grouping results of baffle j32. The area with abnormal density refers to an area consisting of continuous abnormal points whose area density detection values ​​do not meet the preset area density standard. For example, if the area with abnormal density exists in the sub-area of ​​the main coating area (area A), and the baffle corresponding to the area with abnormal density is A2, baffle A2 will be adjusted first.

[0114] Furthermore, the priority adjustment strategy includes a first adjustment priority strategy and a second adjustment priority strategy;

[0115] In the first regulation priority strategy, the baffle j32 corresponding to the area with abnormal surface density has the highest regulation priority;

[0116] In the second adjustment priority strategy, the flow block j32 is adjusted in the following priority adjustment order: the flow block in the main coating area, the flow block in the first critical area, the flow block in the thinning area, the flow block in the second critical area, and the flow block in the blank area;

[0117] In step A4, the first adjustment strategy and the second adjustment priority strategy are selected and used based on the number, distribution, area and surface density value of the surface density abnormality regions in the abnormality analysis results.

[0118] As a further embodiment of the present invention, a critical area is introduced to group the flow blocks, and a priority adjustment strategy for the flow blocks is defined based on the grouping results of the flow blocks, that is, based on different areas. The critical area between area A and area B is called area AB, and the critical area between area B and area C is called area BC. The flow block above area AB is called the flow block AB in the first critical area, and the flow block above area BC is called the flow block BC in the second critical area. One of the priority adjustment strategies for the flow blocks is: adjust according to the following adjustment priority order: group A>group AB>group B>group BC>group C.

[0119] In the case of large surface density fluctuations (large area span, or wide distribution and large number), adjustments are made according to the second adjustment priority strategy of the baffle block; in the case of small surface density fluctuations (small number, concentrated distribution, small area, etc.), or even when there is only a single point of surface density fluctuation, the baffle block corresponding to the surface density fluctuation point in the coating area has the highest adjustment priority and is fine-tuned.

[0120] Furthermore, in step A4, after selecting to use the first adjustment priority strategy to preferentially adjust the flow blocking block j32 corresponding to the abnormal area density area in the abnormality analysis result, the following steps are further performed:

[0121] Step B1: Determine whether the abnormality analysis result corresponding to the real-time acquired surface density detection data meets the preset surface density standard:

[0122] If so, end the use of the first adjustment priority strategy;

[0123] If not, go to step B2;

[0124] Step B2: Select and use the second adjustment priority strategy to adjust the flow block j32.

[0125] When the surface density fluctuation is small, the flow block corresponding to the surface density fluctuation point in the coating area has the highest adjustment priority. If the fine-tuning fails to effectively solve the problem, the second adjustment priority strategy will be used according to the subsequent surface density situation. For example, Figure 9 shown.

[0126] Furthermore, in step A4, the calculation formula 1 for the maximum adjustment stroke of the baffle j32 in the thinned area B and the first critical area AB is as follows:

[0127]

[0128] Wherein, Y represents the maximum adjustment stroke of the flow block j32 in the thinning area B / first critical area AB, m represents a constant value, and X represents the maximum adjustment stroke of the main coating area;

[0129] In step A4, the calculation formula 2 of the maximum adjustment stroke of the baffle j32 in the blank area C and the second critical area BC is expressed as follows:

[0130] Z=Y+n

[0131] Wherein, Z represents the maximum adjustment stroke of the baffle j32 in the blank area C / the second critical area BC, and n is the standard coating thickness of the thinning area B.

[0132] As a further embodiment of the present invention, in order to increase the surface density, the maximum adjustment strokes of the baffles in different groups are limited.

[0133] Assume that the maximum adjustment stroke of the flow blocks in area A, group A, is set to X mm, and the maximum adjustment stroke of the flow blocks in areas AB and B, namely group AB and group B, is set to Y mm. The relationship between Y and X is shown in Formula 1. m can be set to 2. Assume that the maximum adjustment stroke of the flow blocks in area BC and group BC and group C, respectively, is set to Z mm. The relationship between Y and Z is shown in Formula 2.

[0134] like Figure 10 As shown, further, in step A2, the grouping result of the flow blocking blocks j32 includes the flow blocking blocks j32 of each sub-region and the flow blocking blocks j32 of the critical area of ​​two adjacent sub-regions;

[0135] Step A4 includes: when the baffle j32 to be adjusted includes the baffle j32 in the critical area associated with the sub-area with the abnormal surface density area in the abnormality analysis result, executing the following steps:

[0136] Step A41: Determine the ratio of the local area of ​​the baffle j32 in the critical area to be adjusted, which faces the sub-region with the abnormal surface density, to the entire area of ​​the baffle j32:

[0137] If it is not less than the first threshold, execute step A42;

[0138] If it is less than the first threshold, execute step A43;

[0139] Step A42, adjusting the baffle j32 in the critical area to be adjusted using a predetermined unit adjustment stroke as the unit adjustment stroke;

[0140] In step A43, the block is adjusted by assigning a weight to the predetermined unit adjustment stroke as the unit adjustment stroke of the block j32 in the critical area to be adjusted. The calculation formula 3 is as follows:

[0141] H(adjacent)=H×(S1 / S2)

[0142] in,

[0143] H (adjacent) represents the unit adjustment stroke of the baffle j32 in the critical area to be adjusted;

[0144] H indicates the preset unit adjustment stroke;

[0145] S1 represents the local area of ​​the sub-region where the surface density anomaly region exists and the baffle j32 of the critical region to be adjusted faces;

[0146] S2 represents the local area of ​​the baffle j32 in the critical region to be adjusted, which faces the sub-region adjacent to the sub-region where the surface density anomaly region exists.

[0147] Specifically, the first threshold is 1 / 3.

[0148] As a further embodiment of the present invention, Figure 7 As shown, assuming that the dividing line between area A and area B is K AB Line, then K AB The block corresponding to the line is the block of the first critical area, that is, group AB. AB The line divides the block AB into two parts. Assume that the local area of ​​the block AB close to area A is S A , the local area close to area B is S B1 .

[0149] when When the local area of ​​the baffle block AB in zone A is greater than 2 / 3 of the overall area of ​​the baffle block AB, and the local area of ​​the baffle block AB in zone B is less than 1 / 3 of the overall area of ​​the baffle block AB (because the sum of the local areas occupied by the two areas is the overall area of ​​the baffle block AB), the local part of the baffle block AB close to the side of zone A is dominant. At this time, if an abnormal area of ​​surface density appears in zone A (i.e., the main coating area), the priority adjustment strategy is selected for adjustment based on the abnormal analysis results, and the unit adjustment stroke for the adjustment of the baffle block AB is the predetermined unit adjustment stroke. At this time, if an abnormal area of ​​surface density appears in zone B (i.e., the thinning area), it is executed by increasing the weight ratio of the predetermined unit adjustment stroke, and the weight ratio is Assuming that the predetermined unit adjustment stroke of the baffle is H, the unit adjustment stroke after increasing the weight ratio becomes H1, then:

[0150]

[0151] when When the local area of ​​the baffle block AB in area B is greater than 2 / 3 of the total area of ​​the baffle block AB, and the local area of ​​the baffle block AB in area A is less than 1 / 3 of the total area of ​​the baffle block AB, the local part of the baffle block AB close to the side of area B is dominant. At this time, if an abnormal area of ​​surface density appears in area B, the priority adjustment strategy is selected according to the abnormality analysis result, and the unit adjustment stroke of the baffle block AB is the predetermined unit adjustment stroke. At this time, if an abnormal area of ​​surface density appears in area A, it is executed by increasing the weight ratio of the predetermined unit adjustment stroke, and the weight ratio is Assuming that the predetermined unit adjustment stroke of the baffle is H, the unit adjustment stroke after increasing the weight ratio becomes H2, then:

[0152]

[0153] when When the flow block AB is in zone A and in zone B, the proportions of the partial area of ​​the flow block AB in zone A and zone B are both between 1 / 3 and 2 / 3 of the total area of ​​the flow block AB, with neither dominating. The unit adjustment stroke of the flow block AB is a predetermined unit adjustment stroke. A priority adjustment strategy is selected based on the abnormality analysis results.

[0154] Assume that the dividing line between area B and area C is K BC Line, then K BC The block corresponding to the line is the block of the second critical region, that is, group BC. BC The line divides the flow block BC into two parts. Assume that the local area of ​​the flow block BC close to the B area is S B2 , the local area close to area C is S C .

[0155] when When the local area occupied by the baffle block BC in zone B is greater than 2 / 3 of the overall area of ​​the baffle block BC, and the local area occupied by the baffle block BC in zone C is less than 1 / 3 of the overall area of ​​the baffle block BC (because the sum of the local areas occupied by the two areas is the overall area of ​​the baffle block BC), the local part of the baffle block BC close to the side of zone B is dominant. At this time, if an abnormal area of ​​surface density appears in zone B, the priority adjustment strategy is selected according to the abnormality analysis result for adjustment, and the unit adjustment stroke for the adjustment of the baffle block BC is the predetermined unit adjustment stroke. At this time, if an abnormal area of ​​surface density appears in zone C, it is executed by increasing the weight ratio of the predetermined unit adjustment stroke, and the weight ratio is Assuming that the predetermined unit adjustment stroke of the baffle is H, the unit adjustment stroke after increasing the weight ratio becomes H3, then:

[0156]

[0157] when When the local area of ​​the block BC in zone C is greater than 2 / 3 of the total area of ​​the block BC, and the local area of ​​the block BC in zone B is less than 1 / 3 of the total area of ​​the block BC, the local part of the block BC close to zone C is dominant. At this time, if an abnormal area of ​​surface density appears in zone C, the priority adjustment strategy is selected according to the abnormality analysis result, and the unit adjustment stroke of the adjustment of the block BC is the predetermined unit adjustment stroke. At this time, if an abnormal area of ​​surface density appears in zone B, the adjustment is performed by increasing the weight ratio of the predetermined unit adjustment stroke, and the weight ratio is Assuming that the predetermined unit adjustment stroke of the baffle is H, the unit adjustment stroke after increasing the weight ratio becomes H4, then:

[0158]

[0159] when When the flow block BC is in zone B and zone C, the proportions of the partial area of ​​the flow block BC in zone B and zone C are both between 1 / 3 and 2 / 3 of the total area of ​​the flow block BC, with neither dominating. The unit adjustment stroke of the flow block BC is the predetermined unit adjustment stroke. A priority adjustment strategy is selected based on the abnormality analysis results.

[0160] See also Figure 1 The present invention further provides a coating closed-loop system, characterized in that it is used to perform the aforementioned coating surface density control method, comprising:

[0161] An unwinding assembly 1, for unwinding a substrate 11 to be coated;

[0162] The spray assembly 2 is used to spray the slurry onto the substrate 11, and includes a die head. The die head comprises, from top to bottom, an upper die a, an upper gasket d, and a middle die b. The middle die b has an upper die cavity f. The upper gasket d includes an opening area d1. The upper die a has a plurality of flow blocks j32 facing the upper die cavity f. Each flow block j32 is connected to a micro motor j2.

[0163] The oven assembly 5 is used to dry the slurry sprayed onto the substrate 11;

[0164] The detection component 6 is used to perform real-time detection on the substrate 11 after drying to obtain surface density detection data;

[0165] The winding assembly 7 is used to wind up the coated substrate 11;

[0166] The host computer 8 is connected to the detection component 6 and the spray component 2 respectively, and is used to:

[0167] Record the coating area of ​​the die head and the sub-areas formed by the area, as well as the grouping results of the baffle j32 obtained based on the sub-areas;

[0168] Acquire area density detection data from the detection component 6, and analyze the area density detection data to obtain an abnormality analysis result;

[0169] Determine the flow block j32 to be adjusted based on the abnormality analysis result and the grouping result of the flow block j32, generate the flow block adjustment parameter, and send the flow block adjustment parameter to the spray assembly 2;

[0170] The spray assembly 2 is used to drive the micro motor j2 of the die head to adjust the stroke of the baffle j32 based on the baffle adjustment parameters, so as to adjust the coating surface density of the substrate 11.

[0171] Specifically, after the equipment is turned on, and before the system of the present invention is used to automatically adjust the coating area density, the die head's flow block and the distance between the die head and the corresponding backing roller are manually adjusted to ensure that the area density test data is mostly within the preset area density standard. The closed-loop system is then activated, and the flow block is used for real-time fine-tuning until the area density test data stabilizes within the preset area density standard.

[0172] Furthermore, the upper gasket d includes an outer solid area d2 and at least one inner solid area d3;

[0173] The outer physical area d2 includes a left physical area d21, a right physical area d22 and a dorsal physical area d23, and the left physical area d21, the right physical area d22 and the inner physical area d3 are connected to the dorsal physical area d23;

[0174] A first notch is formed on the inner side of the left solid area d21 and the inner side of the right solid area d22, which passes through the first notch from top to bottom.

[0175] The inner solid area d3 is provided with a second notch d31 facing the upper mold a and not penetrating vertically.

[0176] like Figure 3 As shown, the first notch d211 of the left entity area d21 and the first notch d221 of the right entity area d22 represent through notches of the same size.

[0177] Furthermore, the die head also includes a lower die c and a lower gasket e. The lower gasket e is arranged between the lower die c and the middle die b. The lower die c is provided with a lower die cavity g facing the middle die b.

[0178] Furthermore, the coating closed-loop system is a double-sided coating system, and further comprises a back-roll assembly 3 and a pass-roll assembly 4;

[0179] The roller assembly 4 includes a first group of rollers and a second group of rollers, the back roller assembly 3 includes a first back roller 31 and a second back roller 32, the oven assembly 5 includes a first oven 52 and a second oven 51, and the detection assembly 6 includes a first surface density detector 62 and a second surface density detector 61;

[0180] The spraying assembly 2 includes a first coater 21 and a second coater 22, and both the first coater 21 and the second coater 22 include a die head;

[0181] The first set of rollers transfers the substrate 11 unwound by the unwinding assembly 1 to the first back roller 31. The first coater 21 sprays the slurry on the first surface of the substrate at the first back roller 31. The first back roller 31 transfers the substrate 11 to the first oven 52.

[0182] The first surface density detector 62 performs surface density detection on the first surface of the substrate 11 dried in the first oven 52 to obtain surface density detection data of the first surface of the substrate 11;

[0183] The second group of rollers transfers the substrate 11 dried in the first oven 52 to the second back roller 32. The second coater 22 sprays the slurry on the second surface of the substrate 11 at the second back roller 32. The second back roller 32 transfers the substrate 11 to the second oven 51.

[0184] The second surface density detector 61 performs surface density detection on the first surface and the second surface of the substrate 11 dried in the second oven 51 to obtain surface density detection data of both surfaces of the substrate 11 .

[0185] The unwinding assembly 1 includes an unwinding substrate 11 and an unwinding bracket 12 . The substrate 11 is used for feeding the substrate of the coating closed-loop system, and the unwinding bracket 12 is used for supporting, unwinding and transmitting the substrate 11 .

[0186] The spray assembly 2 includes a first coater 21 and a second coater 22 , which have the same structure and components and both include the aforementioned die head, and are located on both sides of the coating closed loop system, respectively used for spraying the two sides of the substrate.

[0187] The back roller assembly 3 includes a first back roller 31 and a second back roller 32 , and is used to control the tension of the substrate 11 and maintain the transmission of the substrate 11 .

[0188] The roller assembly is used to transmit the substrate 11. In a double-sided coating system, Figure 1As shown, the first group of rollers includes a first roller 41 and a second roller 42, the second group of rollers includes a third roller 43 and a fourth roller 44, and the roller assembly 4 also includes a fifth roller 45 and a sixth roller 46. The first roller 41 and the second roller 42 are arranged between the first back roller 31 and the unwinding assembly 1, the third roller 43 and the fourth roller 44 are arranged between the first surface density detector 62 and the second back roller 32, the fifth roller 45 is arranged between the second back roller 32 and the second surface density detector 61, and the sixth roller 46 is arranged between the second surface density detector 61 and the winding assembly 7. The third roller 43 and the fourth roller 44 are used in combination and change direction while transmitting, so that the first coater 21 sprays the slurry to one side of the substrate 11, and the second coater 22 sprays the slurry to the other side of the substrate 11.

[0189] The oven assembly 5 includes a first oven 52 and a second oven 51 , which are used to dry the slurry coated on the substrate.

[0190] The detection assembly 6 includes a first surface density detector 62 and a second surface density detector 61, which are respectively used to measure the single-surface density after drying in the first oven 52 and the double-surface density after drying in the second oven 51.

[0191] The winding assembly 7 includes a winding support 71 for winding and supporting the double-sided coated electrode 72 after drying in the first oven 52 and the second oven 51 .

[0192] The host computer 8 communicates with the spray assembly 2, the first surface density detector 62, and the second surface density detector 61, respectively. The host computer 8 receives the surface density detection data from the first surface density detector 62 and the second surface density detector 61, analyzes the abnormality analysis results, and generates the flow block adjustment parameters based on the abnormality analysis results. The spray assembly 2 adjusts the flow block j32 up and down according to the flow block adjustment parameters, thereby achieving dynamic and efficient automatic adjustment of the coating surface density. In special circumstances, the staff can manually set the flow block adjustment parameters on the host computer, that is, manually adjust the flow block. Manual adjustment takes priority over automatic adjustment.

[0193] The double-sided coating working principle of the present invention is as follows.

[0194] The unwinding bracket 12 of the unwinding assembly 1 unwinds the substrate 11, which is then transferred to the first backing roller 31 for tensioning via the first and second rollers 41 and 42. The slurry is pressure-buffered in the upper and lower cavities f and g of the die head of the first coater 21, flows through the upper and lower lip portions h and i for fluid shaping, and is then sprayed onto the first surface of the substrate 11. The wet film on the substrate 11 is dried in the first drying oven 52 to form a single-sided dry film. After exiting the first drying oven 52, the single-sided surface density is measured by the first surface density meter 62. The single-sided dry film then passes through the third and fourth rollers 43 and 44, where it is redirected and transferred to the second backing roller 32 for tensioning. This ensures that the other side of the single-sided dry film faces the die head of the first coater 22 for coating. The resulting wet film on the other side passes through the fifth roller 45 and then ascends to the second drying oven 51 for drying, forming a double-sided dry film. After the double-sided dry film exits the second drying oven 51, it is tested for double-sided surface density by the second surface density detector 61, passed downhill by the sixth roller 46, and wound by the winding bracket 71 of the winding assembly 7 to form a winding pole piece 72. During the entire transmission process of the pole piece, the first surface density detector 62 of the lower layer and the second surface density detector 61 of the upper layer transmit the surface density detection data to the host computer 8 for processing and analysis, and provide intuitive feedback. At the same time, based on the data of the second surface density detector 61 of the upper layer and the first surface density detector 62 of the lower layer, the surface density abnormality is analyzed and the spraying assembly 2 is issued an adjustment command. The micro motor j2 of the baffle block j32 drives the baffle block j32 to move up and down, and the surface density of the single-sided dry film and the double-sided dry film is adjusted by adjusting the cavity pressure. The adjusted surface density data is then detected by the upper surface density meter 61 and the lower surface density meter 62 and transmitted to the host computer 8, finally forming a closed-loop adjustment system, realizing unmanned production and rapid adjustment, greatly reducing production and manufacturing costs.

[0195] The above are only preferred embodiments of the present invention and do not limit the implementation mode and protection scope of the present invention. For those skilled in the art, it should be aware that all solutions obtained by equivalent substitutions and obvious changes made using the description and illustrations of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for controlling coating surface density, characterized in that: The method comprises a coating die head, wherein the die head comprises an upper die, an upper gasket and a middle die from top to bottom, the middle die is provided with an upper die cavity, the upper gasket comprises an opening area, the upper die is provided with a plurality of flow blocks facing the upper die cavity, each of the flow blocks is connected to a micro motor, and the method comprises the following steps: Step A1, partitioning the coating area into a plurality of sub-areas based on the opening area of ​​the upper gasket; Step A2, grouping the upper baffles according to the sub-areas of the coating area to obtain a grouping result of the baffles; Step A3, coating the substrate with the slurry using the die head, and acquiring surface density detection data after coating in real time; Step A4: Analyze the surface density detection data to obtain an abnormality analysis result, determine the baffle to be adjusted based on the abnormality analysis result and the grouping result of the baffle, and adjust the stroke of the baffle to be adjusted to adjust the coating surface density of the substrate.

2. A coating surface density control method according to claim 1, characterized in that, In step A1, the coating area is divided into sub-areas according to the main coating area, the thinning area and the blank area. The dividing line between two adjacent sub-areas forms a critical area. The dividing line between the main coating area and the thinning area serves as the first critical area, and the dividing line between the thinning area and the blank area serves as the second critical area. In step A2, the flow blocks are grouped into flow blocks in the main coating area, flow blocks in the thinning area, and flow blocks in the blank area, and the flow blocks in the first critical area and the flow blocks in the second critical area are marked to obtain a grouping result of the flow blocks; In the step A2, a priority adjustment strategy of the blocking block is further defined according to the grouping result of the blocking block; In the step A4, the corresponding baffles are adjusted based on the abnormality analysis results, the grouping results of the baffles, and the priority adjustment strategy of the baffles, so as to adjust the coating surface density of the substrate.

3. A coating surface density control method according to claim 2, characterized in that, The priority adjustment strategy includes a first adjustment priority strategy and a second adjustment priority strategy; In the first adjustment priority strategy, the flow blocking block corresponding to the area with abnormal surface density has the highest adjustment priority; In the second adjustment priority strategy, the flow blocks are adjusted in the following priority adjustment order: the flow blocks in the main coating area, the flow blocks in the first critical area, the flow blocks in the thinning area, the flow blocks in the second critical area, and the flow blocks in the blank area; In step A4, the first adjustment strategy and the second adjustment priority strategy are selected and used based on the number, distribution, area and surface density value of the surface density abnormality regions in the abnormality analysis result.

4. A coating surface density control method according to claim 3, characterized in that, In step A4, after selecting to use the first adjustment priority strategy to preferentially adjust the flow blocking blocks corresponding to the surface density abnormal area in the abnormality analysis result, the following steps are further performed: Step B1: Determine whether the abnormality analysis result corresponding to the area density detection data acquired in real time meets the preset area density standard: If yes, end the use of the first adjustment priority strategy; If not, go to step B2; Step B2: Select and use the second adjustment priority strategy to adjust the choke.

5. A coating surface density control method according to claim 2, characterized in that: In step A4, the calculation formula for the maximum adjustment stroke of the baffle in the thinning area and the first critical area is expressed as follows: Wherein, Y represents the maximum adjustment stroke of the baffle block in the thinning area / the first critical area, a represents a constant value, and X represents the maximum adjustment stroke of the main coating area; In step A4, the calculation formula for the maximum adjustment stroke of the baffle block in the blank area and the second critical area is expressed as follows: Z=Y+n Wherein, Z represents the maximum adjustment stroke of the baffle block in the blank area / the second critical area, and b is the standard coating thickness of the thinning area.

6. A coating surface density control method according to claim 1, characterized in that: In step A2, the grouping result of the flow blocks includes the flow blocks in each sub-area and the flow blocks in the critical areas of two adjacent sub-areas; The step A4 includes: when the baffles to be adjusted include baffles in the critical area associated with the sub-area with the area density abnormality in the abnormality analysis result, performing the following steps: Step A41: Determine the ratio of the local area of ​​the baffle block in the critical area to be adjusted, which faces the sub-region where the surface density anomaly exists, to the entire area of ​​the baffle block: If it is not less than the first threshold, execute step A42; If it is less than the first threshold, execute step A43; Step A42, adjusting the baffle block by taking a predetermined unit adjustment stroke as the unit adjustment stroke of the baffle block in the critical area to be adjusted; In step A43, the flow block is adjusted by assigning a weight to the predetermined unit adjustment stroke as the unit adjustment stroke of the flow block in the critical area to be adjusted. The calculation formula is as follows: H(adjacent)=H×(S1 / S2) in, H (adjacent) represents the unit adjustment stroke of the baffle in the critical area to be adjusted; H represents the predetermined unit adjustment stroke; S1 represents the local area of ​​the sub-region where the surface density anomaly area exists and the baffle block in the critical region to be adjusted faces; S2 represents the local area of ​​the baffle in the critical region to be adjusted, which faces the sub-region adjacent to the sub-region where the surface density anomaly region exists.

7. A coating closed loop system, characterized in that: A method for controlling coating surface density according to any one of claims 1 to 6, comprising: An unwinding component, used for unwinding the substrate to be coated; A spray assembly for spraying slurry onto a substrate, comprising a die head, wherein the die head comprises an upper die, an upper gasket, and a middle die from top to bottom, wherein the middle die is provided with an upper die cavity, the upper gasket comprises an opening area, and the upper die is provided with a plurality of flow blocks facing the upper die cavity, each of the flow blocks being connected to a micro motor; An oven assembly, used for drying the slurry sprayed onto the substrate; A detection component is used to perform real-time detection on the substrate after drying to obtain surface density detection data; A winding component is used to wind up the coated substrate; The host computer is connected to the detection component and the spray component respectively, and is used to: Recording the coating area of ​​the die head and the sub-areas formed by the sub-areas, as well as the grouping results of the flow blocks obtained according to the sub-areas; Acquiring the surface density detection data from the detection component, and analyzing the surface density detection data to obtain an abnormality analysis result; Determining the flow block to be adjusted based on the abnormality analysis result and the grouping result of the flow blocks, generating flow block adjustment parameters, and sending the flow block adjustment parameters to the spray assembly; The spray assembly is used to drive the micro motor of the die head to adjust the stroke of the baffle block based on the baffle block adjustment parameter, so as to adjust the coating surface density of the substrate.

8. A coating closed-loop system according to claim 7, characterized in that: The upper gasket includes an outer solid area and at least one inner solid area; The outer physical area includes a left physical area, a right physical area and a back physical area, and the left physical area, the right physical area and the inner physical area are connected to the back physical area; A first notch is formed on the inner side of the left solid area and the inner side of the right solid area, which passes through the first notch from top to bottom; The inner solid area is provided with a second notch facing the upper mold and not penetrating vertically.

9. A coating closed-loop system according to claim 7, characterized in that: The die head further comprises a lower die and a lower gasket, wherein the lower gasket is arranged between the lower die and the middle die, and the lower die is provided with a lower die cavity facing the middle die.

10. A coating closed loop system according to claim 9, characterized in that: The coating closed-loop system is a double-sided coating system, and also includes a back roller assembly and a passing roller assembly; The roller assembly includes a first group of rollers and a second group of rollers, the back roller assembly includes a first back roller and a second back roller, the oven assembly includes a first oven and a second oven, and the detection assembly includes a first surface density detector and a second surface density detector; The spraying assembly includes a first coater and a second coater, and the first coater and the second coater both include the die head; The first group of rollers transfers the substrate unwound by the unwinding assembly to the first back roller, the first coater sprays the slurry on the first surface of the substrate at the first back roller, and the first back roller transfers the substrate to the first oven; The first surface density detector performs surface density detection on the first surface of the substrate dried in the first oven to obtain surface density detection data of the first surface of the substrate; The second group of rollers transfers the substrate dried in the first oven to the second back roller, the second coater sprays the slurry on the second surface of the substrate at the second back roller, and the second back roller transfers the substrate to the second oven; The second surface density detector performs surface density detection on the first surface and the second surface of the substrate dried in the second oven to obtain the surface density detection data of the double surfaces of the substrate.

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