Electrode Coating Roll Map for Accurate Defect Location Tracking
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Solution Overview
Problem
Existing methods for marking defects in electrode coating processes of lithium secondary batteries are inadequate, as they often misidentify the location of defects and fail to provide comprehensive historical data, making it difficult to trace defects back to their origin in the manufacturing process.
Innovation Solution
A roll map system that visually displays quality-related and defect-related data on a simulated electrode shape, allowing for accurate tracking and analysis of defects and quality information throughout the electrode coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If physical marking is done directly on the electrode, then defect information can be recorded, but the exact location of defects cannot be accurately displayed and quality correlation analysis becomes difficult
Solution Approach 1:
The patent creates a virtual copy of the electrode in the form of a roll map that replicates the electrode's physical characteristics and defect locations. This virtual model allows precise defect location tracking without physically marking the actual electrode, thereby preserving exact location information while enabling comprehensive quality analysis throughout the manufacturing process.
Solution Approach 2:
The patent transitions from two-dimensional physical marking on the electrode surface to a three-dimensional virtual roll map that incorporates longitudinal position, transverse position, and defect type dimensions. This dimensional expansion enables precise defect location identification and facilitates quality correlation analysis across different manufacturing stages.
2Duration of action of moving object
If marking is done after battery assembly, then secondary battery process history can be checked, but electrode coating process defect history cannot be traced
Solution Approach 1:
The patent implements preliminary action by creating the roll map during the electrode coating process itself, rather than waiting until after battery assembly. This early establishment of the quality map preserves defect information from the electrode manufacturing stage, enabling continuous tracking throughout subsequent assembly processes and facilitating root cause analysis.
Solution Approach 2:
The roll map serves multiple functions across different manufacturing stages: it records electrode coating defects, tracks quality through assembly processes, and enables correlation analysis between electrode quality and final battery performance. This multi-functional quality tracking system eliminates information loss across process boundaries.
3Loss of information
If comprehensive quality data is collected throughout the process, then defect analysis is improved, but data visualization and understanding become complex
Solution Approach 1:
The patent segments comprehensive quality data into distinct categories (defect type, location, severity, process stage) and displays them as separate visual elements on the roll map. This segmentation allows operators to understand different aspects of quality independently while maintaining access to the complete quality picture, thereby simplifying data interpretation without losing information completeness.
Solution Approach 2:
The patent uses color coding to represent different defect types, severity levels, and process stages on the roll map. This visual encoding transforms complex quantitative quality data into intuitive color-based information, enabling operators to quickly understand quality status and defect characteristics without analyzing raw data, thus improving ease of operation while maintaining information completeness.
Data Source
AI summary
A roll map of an electrode coating process includes a roll map bar and a representation part. The roll map bar is displayed on a screen in synchronization with movement of an electrode between an unwinder and a rewinder while being coated with an electrode slurry in a roll-to-roll state. The roll map bar is displayed in the form of a bar by simulating the electrode in the roll-to-roll state. The representation part is configured to visually show either one of or both quality-related and defect-related acquired data associated with the electrode coating process. The acquired data is shown at a certain location on the roll map bar corresponding to a location in the electrode at which the data is measured. A roll map of an electrode coating process is generated by a process. A roll map of an electrode coating process is generated by a system.