Rechargeable Battery Coating Width Control via Image Inspection
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Solution Overview
Problem
The width of the mixture paste applied to electrode substrates in rechargeable batteries can become unstable due to surface tension, leading to potential short-circuiting issues, which necessitates precise control over the widths of both the mixture and insulation layers.
Innovation Solution
A method involving a simultaneous coating process using a dispenser to apply the mixture and insulation pastes, with an image inspection unit adjusting the distance and flowrate to ensure the mixture paste width approaches a target value, while the insulation paste width is also adjusted to prevent short-circuiting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mixture paste is applied to the electrode substrate, then the electrode plate is formed, but the coating width becomes unstable due to surface tension
Solution Approach 1:
The patent employs an image inspection unit to detect the actual coating width of the mixture paste, and a controller adjusts the dispenser gap distance based on this feedback to maintain the coating width within a target range, thereby resolving the instability caused by surface tension
Solution Approach 2:
The system dynamically adjusts the gap distance between the dispenser and electrode substrate during the coating process based on real-time width detection, transforming a static coating process into a dynamic one that adapts to width variations
2Reliability
If the coating width is precisely controlled, then short-circuiting is prevented, but the process complexity increases
Solution Approach 1:
The patent implements a closed-loop control system where the image inspection unit continuously monitors the coating width and feeds this information back to the controller, which adjusts the dispenser gap to ensure the mixture paste and insulation paste do not overlap, thereby preventing short-circuiting
Solution Approach 2:
The patent replaces manual or open-loop mechanical coating control with an automated optical inspection and feedback-controlled mechanical adjustment system, using image processing and automated gap adjustment to achieve precise width control
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 method stabilizes the coating width of the mixture paste and ensures the insulation layer is properly formed, effectively preventing short-circuiting and improving the manufacturing yield of rechargeable batteries.
Implementation Method 1
an image inspection unit, so as to detect a coating width of the mixture paste and a coating width of the insulation paste
Implementation Method 2
a flowrate adjustment process for changing a flowrate of the insulation paste dispensed from the dispenser
Implementation Method 3
The width of the mixture paste applied to the electrode substrate may become unstable due to surface tension acting on a widthwise end of the mixture paste
Data Source
AI summary
A method for manufacturing a rechargeable battery includes a simultaneous coating process for simultaneously coating an electrode substrate with one strip of a mixture paste and two strips of an insulation paste dispensed from a dispenser so that each widthwise end of the strip of the mixture paste is adjacent to a different strip of the insulation paste. The simultaneous coating process includes a gap adjustment process for changing a distance between the dispenser and the electrode substrate based on a coating width of the mixture paste, detected in the simultaneous coating process by an image inspection unit, so that the coating width of the mixture paste approaches a target value.