Application Roller Masking Structure for Battery Coating
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Solution Overview
Problem
Existing application roller techniques result in increased edge thickness and unstable edge position of the coating film due to the use of masking films, which interfere with lithium ion battery performance.
Innovation Solution
An application roller design featuring a large diameter portion with small diameter portions at both ends, where a resin layer is overlaid and processed to form a masking portion and application groove, eliminating the need for a masking film and stabilizing the edge position of the coating film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a masking film of given thickness (10 to 20 μm) is used to prevent coating solution leakage, then the masking film maintains structural integrity and prevents fractures, but the masking film causes increased edge thickness of the coating film due to surface tension drawing the coating solution to the edge
Solution Approach 1:
The invention extracts and eliminates the masking film from the coating system entirely. Instead of using a separate masking film wrapped around the application roller, the roller surface itself is structured with masking portions formed by processing the resin layer directly on the roller body, integrating the masking function into the roller structure and eliminating the harmful edge thickness effect
Solution Approach 2:
The invention merges the masking function with the application roller structure itself. The masking portions are formed by processing the resin layer overlaid on the roller body, combining what were previously separate components (application roller and masking film) into a single integrated structure that eliminates the interface between them
2Manufacturing precision
If the masking film thickness is reduced to minimize step height at the edge, then the coating film edge thickness is reduced, but the masking film becomes prone to fractures and wrinkles due to friction contact with the rotating roller
Solution Approach 1:
The masking portions are formed by processing the resin layer that is already overlaid on the roller body, merging the masking function with the roller structure itself. This eliminates the separate masking film component that suffers from thickness-related failures, while the resin layer provides sufficient durability through its bonding to the roller surface
3Adaptability or versatility
If a masking film is wrapped around the application roller to achieve local coating, then the application roller can be easily adapted for different product specifications by changing the masking film shape, but the position of the masking film relative to the application roller becomes unstable
Solution Approach 1:
The masking portions are formed by processing the resin layer that is overlaid on the roller body, merging the masking function with the roller structure itself. This integration ensures stable relative positioning between the masking portions and the application groove, eliminating the position instability inherent in wrapped masking films while maintaining adaptability through resin layer reconfiguration
4Reliability
If the masking film thickness is increased to prevent fractures, then the masking film maintains structural integrity, but the step height at the edge increases causing greater coating solution drawing by surface tension
Solution Approach 1:
The invention extracts and eliminates the masking film from the coating system entirely. Instead of using a separate masking film wrapped around the application roller, the roller surface itself is structured with masking portions formed by processing the resin layer directly on the roller body, integrating the masking function into the roller structure and eliminating the harmful edge thickness effect
Solution Approach 2:
The invention merges the masking function with the application roller structure itself. The masking portions are formed by processing the resin layer overlaid on the roller body, combining what were previously separate components (application roller and masking film) into a single integrated structure that eliminates the interface between them
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces the increased edge thickness of the coating film to 10 nm or less, minimizing its impact on battery performance and stabilizing the edge position, thereby improving the precision and consistency of the coating process.
Implementation Method 1
a phenomenon occurs in which a coating solution P is drawn by surface tension to an edge F1 of a masking film F having the given thickness
Data Source
AI summary
A manufacturing method of an application roller that applies a coating solution onto a surface of a substrate, wherein the application roller includes a roller body that includes a large diameter portion and small diameter portions coaxially extended from both ends of the large diameter portion, the manufacturing method includes: overlaying a resin layer on at least an outer periphery of each of the small diameter portions; forming a masking portion on the outer periphery of each of the small diameter portions by processing an outer periphery of the resin layer; and forming an application groove portion on an outer periphery of the large diameter portion.