Multi-Stage Coating Drying Control for Binder-Safe Throughput
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Solution Overview
Problem
Existing drying processes for producing coatings on substrates, such as battery electrodes and solar cells, face challenges in efficiently adjusting drying conditions to improve product quality and process efficiency, particularly in terms of throughput and energy consumption.
Innovation Solution
A computer-implemented method and system that adjust the drying process by employing a model to generate predictive values for setting parameters of dryers across multiple consecutive drying stages, allowing for independent adjustment of each stage to optimize drying conditions based on substrate layout, preparation composition, and substrate properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a high evaporation rate is used during initial and final drying stages, then the total drying time is reduced, but the binder may deplete at film domains close to the substrate
Solution Approach 1:
The drying process is divided into multiple drying stages with different evaporation rates. The method segments the drying process into at least two drying stages, where each stage has optimized drying conditions to prevent binder depletion while maintaining efficient drying time.
Solution Approach 2:
The drying conditions are dynamically adjusted during the drying process. The method varies drying parameters such as temperature, air flow rate, and humidity levels across different drying stages to optimize both drying time and prevent binder depletion at different phases of the drying process.
2Manufacturing precision
If drying conditions are optimized for product quality, then coating performance improves, but energy consumption increases
Solution Approach 1:
The method optimizes drying parameters including temperature, relative humidity, and air flow rate to achieve high coating quality while managing energy consumption. By carefully controlling these parameters across different drying stages, the system achieves optimal coating performance without excessive energy use.
Solution Approach 2:
The drying process uses periodic variations in drying conditions with at least two drying stages having different parameter settings. This periodic adjustment allows the system to achieve high coating quality while reducing overall energy consumption by using lower energy settings during certain phases.
3Manufacturing precision
If multiple drying zones are used to control drying stages, then drying precision improves, but device complexity increases
Solution Approach 1:
The method enables a single drying zone to perform multiple drying stages by dynamically adjusting drying parameters. This multi-functional approach allows the system to achieve precise drying stage control without requiring multiple separate drying zones, thereby reducing device complexity while maintaining drying precision.
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 enhances the quality of the coating while reducing energy consumption and increasing production efficiency, allowing for better control and flexibility in the drying process, independent of the number or position of drying zones.
Implementation Method 1
the at least one drying process comprises at least two consecutive drying stages after which the at least one coating is produced
Implementation Method 2
at least one model configured to generate at least one predictive value for at least one setting parameter for at least one associated dryer being used during at least one of the drying stages
Data Source
AI summary
A computer-implemented method and system for adjusting at least one drying process designated for producing at least one coating on at least one substrate are provided herein. The at least one drying process is applied to at least one preparation deposited on the at least one substrate, wherein the at least one drying process comprises at least two consecutive drying stages after which the at least one coating is produced Further disclosed are a related method and system for continuously producing the at least one coating on the at least one substrate.