Doctor Blade Surface Material for Battery Separator Coating
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Solution Overview
Problem
Conductive metallic abrasion powder from worn-down doctor blades contaminates separators in battery production, leading to short circuits due to the use of metal-edged doctor blades with coating solutions containing hard fillers like alumina.
Innovation Solution
A doctor blade with a surface made from a non-conductive material, such as resin or ceramic, is used to scrape off coating solutions containing fillers from the coating roller, preventing the creation of conductive abrasion powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a metal-edged doctor blade is used to scrape off coating solution containing hard fillers like alumina, then the doctor blade can effectively remove the coating solution, but the filler wears down the metal edge section creating conductive metallic abrasion powder that contaminates the separator and causes short circuits
Solution Approach 1:
The invention changes the material parameter of the doctor blade edge from metal to non-conductive material (resin or ceramic), fundamentally altering the electrical conductivity property while maintaining the scraping function. This parameter change eliminates the generation of conductive metallic abrasion powder that causes short circuits in battery separators.
Solution Approach 2:
The doctor blade is constructed as a composite structure combining a metal base section with a non-conductive edge section made of resin or ceramic. This composite design allows the blade to maintain structural strength from the metal base while the non-conductive edge prevents conductive contamination during the scraping process.
2Object-affected harmful factors
If a non-conductive material is used for the doctor blade surface, then conductive abrasion powder is prevented, but the durability and wear resistance may be reduced compared to metal
Solution Approach 1:
The composite structure combines metal base section for durability and structural integrity with non-conductive edge section for contamination prevention. This division of functional requirements allows each material to excel at its specific role, extending overall blade service life while maintaining non-conductive properties.
Solution Approach 2:
The non-conductive edge section is designed as a replaceable component that can be renewed when worn. This approach allows the expensive metal base to be reused while only replacing the cheaper non-conductive edge, effectively extending the overall blade lifecycle and reducing long-term costs.
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
Prevents battery malfunctions like short circuits by ensuring the abrasion powder is non-conductive, maintaining the quality of the coating process over extended lengths and reducing the frequency of doctor blade replacement.
Implementation Method 1
the filler in the coating solution wears down the edge section of the doctor blade
Data Source
AI summary
Wearing down of a doctor blade by a filler contained in a coating solution is prevented. The doctor blade is for scraping off the coating solution, containing the filler, from a circumferential surface of a coating roller, the coating roller being for applying the coating solution to a battery member being conveyed. A surface of the doctor blade is made from an ultra-high molecular weight polyethylene.