Anilox Roller Blank Regions for Battery Coating Consistency
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Solution Overview
Problem
Existing anilox rollers used in battery coating processes suffer from poor coating consistency due to substrate wrap angle fluctuations and potential substrate scratching, particularly when using stepped rollers like microgravure rollers.
Innovation Solution
The anilox roller design incorporates annular bosses with blank regions and chamfers to prevent slurry bonding at joint edges, reducing substrate wrap angle fluctuations and substrate scratching, while maintaining etching precision and controlling production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a stepped anilox roller is used to avoid interference during coating, then the roller can perform coating processing, but the coating consistency deteriorates due to substrate wrap angle fluctuations and edge scratching
Solution Approach 1:
The patent applies local quality by creating blank regions (areas without etched anilox) at specific locations on the annular boss - namely between the anilox region and the first side surface, and between the anilox region and the second side surface. This localized modification prevents slurry bonding at the joint edges where wrap angle fluctuations occur, thereby improving coating consistency without compromising the overall coating processing capability of the roller
2Device complexity
If the annular boss joint edges contact the substrate, then the roller structure is simple, but substrate scratching occurs and coating width varies
Solution Approach 1:
The patent introduces blank regions at the joint edges of the annular boss where the first side surface meets the circumferential surface and where the second side surface meets the circumferential surface. These blank regions prevent slurry from bonding at the joint edges, eliminating the source of substrate scratching while maintaining the overall simplicity of the roller structure
Solution Approach 2:
The patent performs preliminary action by pre-defining blank regions at the potential problem areas (joint edges of the annular boss) before the coating process begins. This preventive measure ensures that slurry cannot bond at these critical locations, thereby preventing substrate scratching and coating width variation before they can occur
3Manufacturing precision
If blank regions are added to prevent slurry bonding, then coating consistency improves, but etching difficulty increases
Solution Approach 1:
The patent segments the annular boss surface into distinct regions: the anilox region with etched patterns for coating, and the blank regions without etching at the joint edges. This segmentation allows the etching process to be focused only on the necessary anilox region, while the blank regions serve as non-etched zones that prevent slurry bonding, thus improving coating consistency without unnecessarily increasing etching complexity
Data Source
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AI summary
The present application provides an anilox roller and a coating apparatus, which belong to the technical field of battery coating devices. The anilox roller includes a roller body and an annular boss formed on a surface of the roller body. The annular boss extends in a circumferential direction of the roller body. The annular boss includes a circumferential surface, a first side surface, and a second side surface. The first side surface and the second side surface face each other in an axial direction of the roller body. The circumferential surface connects the first side surface and the second side surface, and the circumferential surface includes an anilox region having an etched anilox. A first blank region without an etched anilox is arranged between the anilox region and the first side surface. By arranging the first blank region without an etched anilox between the anilox region and the first side surface, a slurry will not be bonded near a joint of the first side surface and the circumferential surface of the annular boss, which reduces the possibility of a change of a substrate coating width caused by a wrap angle fluctuation of an edge of the annular boss on the substrate, and improves the coating consistency of the anilox roller when coating the slurry.