Intermittent Battery Electrode Coating Synchronization
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Solution Overview
Problem
In intermittently coated battery electrode manufacturing, positional displacement between active material layers on the front and back surfaces of the collector leads to battery discards due to irregular surfaces and erroneous detection of the front end, affecting battery characteristics.
Innovation Solution
Forming a front end indicator on the collector where the active material is not coated, using this indicator to synchronize the coating on both surfaces, ensuring symmetrical and accurate placement of active material layers without displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If intermittent coating is used to eliminate unused coating layers, then material waste is reduced, but positional displacement between front and back coating layers occurs
Solution Approach 1:
A front end indicator (mark) is introduced as an intermediary reference element on the collector. This indicator serves as a mediator between the coating process and the collector, enabling precise synchronization of coating application on both surfaces by providing a common reference point that both coating heads can detect and align to, thereby eliminating positional displacement while maintaining intermittent coating efficiency
2Manufacturing precision
If detection signal is used to control coating timing, then coating synchronization is improved, but erroneous detection of front end position occurs due to irregular surfaces
Solution Approach 1:
Instead of directly detecting the irregular front end of the coating layer, a simplified front end indicator (mark) is created as a copy or representation of the true front end position. This indicator has a regular, easily detectable form that accurately represents the coating front end position without the complications of surface irregularities, enabling reliable detection and synchronization
Data Source
AI summary
An intermittently coated battery electrode manufacturing method capable of preventing a positional displacement from occurring between a first surface of a collector and a second surface opposed to the first surface. The intermittently coated battery electrode manufacturing method includes: forming, at a part of a strip-shaped collector where an active material is not coated, a front end indicator indicating a front end of the active material to be intermittently coated on the collector; performing coating of the active material on a first surface of the collector based on a detection signal of the front end indicator to form an intermittent coating layer; and starting coating of the intermittent coating layer on a second surface opposite to the first surface based on the detection signal of the same front end indicator as that used for forming the active material coating layer on the first surface.