Battery Separator Expander Roll Spacing for Wrinkle Control
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Solution Overview
Problem
Conventional battery separator production methods face challenges in creating a sufficient workspace for operations while preventing wrinkles, due to the short distance between adjacent transfer rollers in the transfer system.
Innovation Solution
Incorporating an expander roll into the transfer system, with the expander roll and the subsequent transfer roller spaced between 1m to 10m apart, to create a workspace and prevent wrinkles during the production of battery separators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the roller span between adjacent transfer rollers is kept short (not more than 1m) to prevent wrinkles in the battery separator, then wrinkle prevention is improved, but the work space for production operations becomes insufficient
Solution Approach 1:
The transfer system is segmented into multiple zones with different roller span characteristics. The expander roll creates a localized expansion zone that allows longer spans (1-10m) in specific areas for work space, while other areas maintain shorter spans for wrinkle prevention. This segmentation enables different regions to serve different functions simultaneously.
Solution Approach 2:
The expander roll acts as an intermediary element between transfer rollers. It mediates the tension and spacing between rollers, allowing the battery separator to be expanded and stabilized in a controlled manner over a longer distance, thus creating work space without causing wrinkles through uncontrolled tension variations.
2Area of stationary object
If the roller span is increased to obtain work space for production operations, then work space is improved, but wrinkles appear in the battery separator
Solution Approach 1:
The expander roll introduces dynamic control to the transfer system. By actively expanding and controlling the battery separator passage between the expander roll and transfer roller, the system can maintain optimal tension and spacing over longer distances, enabling work space expansion without wrinkle formation.
Solution Approach 2:
The invention changes the physical parameters of the transfer system by introducing an expander roll that actively modifies the passage dimensions and tension characteristics. This parameter change allows the system to maintain stability over longer roller spans (1-10m) compared to conventional short spans, thus providing work space while preventing wrinkles.
Data Source
AI summary
A transfer system includes an expander roll for removing a wrinkle in a separator original sheet, and (i) the expander roll and (ii) a transfer roller immediately followed by or following the expander roll are spaced from each other at a distance of not less than 1 m and not more than 10 m.