Battery Electrode Insulation Coating with Wet Thickness Feedback
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Solution Overview
Problem
Conventional battery manufacturing methods face challenges in precisely controlling the thickness and position of insulation coatings on battery electrodes, leading to inefficiencies in material usage, time, and energy consumption.
Innovation Solution
A method and system for real-time estimation and control of insulation coating thickness by determining the indicative wet thickness of the insulator material during deposition, allowing for accurate adaptation of the deposition process to achieve precise positioning and deposition of the solid insulation coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional insulation coating deposition methods are used, then the coating can be applied to the substrate, but the thickness and position control of the insulation coating is imprecise
Solution Approach 1:
The system performs preliminary measurement of the wet thickness during the deposition process itself, before the coating is fully dried. This allows the thickness to be measured and adjusted during application, ensuring precise final thickness and position control without requiring post-processing measurements or adjustments.
Solution Approach 2:
The measurement system provides real-time feedback on the wet thickness of the insulation coating during deposition. This feedback loop enables continuous adjustment of the deposition parameters to maintain the desired thickness and position, directly improving manufacturing precision through active control.
2Productivity
If conventional deposition processes are used without real-time measurement, then the process is simpler, but material usage, time, and energy consumption are inefficient
Solution Approach 1:
The deposition system performs self-measurement of the coating thickness during the process using integrated sensors. This self-service capability allows the system to automatically monitor and adjust its own operation, improving efficiency through real-time optimization without requiring complex external measurement and control systems.
Solution Approach 2:
The system replaces complex mechanical measurement and adjustment mechanisms with optical or electromagnetic sensing methods. This substitution reduces mechanical complexity while enabling precise real-time measurement and control of the insulation coating deposition process, improving overall manufacturing efficiency.
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
This approach enables precise control of insulation coating deposition, reducing material, time, and energy requirements while improving the quality of battery products, thereby enhancing manufacturing efficiency and cost-effectiveness.
Implementation Method 1
depositing an insulator material on the substrate and/or on the active material such as to extend over a boundary between the active material and the substrate
Implementation Method 2
wherein the liquid component of the insulator material evaporates in the course of manufacturing a battery
Data Source
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AI summary
Disclosed is a method of manufacturing a battery, particularly a secondary battery. An active material is deposited on a substrate. An insulator material is deposited on the substrate such as to extend over a boundary between the active material and the substrate. The insulator material includes an insulator component and a liquid component. A indicative wet thickness of the insulator material is determined at a position on the substrate that is offset from the boundary by a characteristic measurement distance. The depositing of the insulator material is adapted as a function of the indicative wet thickness.