Dry Electrode Sheet Roller Gap Control for Thickness Precision
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Solution Overview
Problem
Existing electrode manufacturing processes for secondary batteries, particularly the dry electrode process, face challenges in controlling the thickness of the dry electrode sheet, which affects the quality and efficiency of the manufacturing process.
Innovation Solution
An apparatus and method involving a material feeder, sheet forming rollers, force sensors, thickness sensors, and a controller to adjust the gap between the rollers based on force measurements, ensuring the thickness of the electrode sheet matches a target value, using linear or rotary gap adjusters and controlling the material feeder's opening ratio or discharge pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dry electrode process is used to manufacture electrode sheets, then the manufacturing quality and efficiency are improved, but the thickness control of the electrode sheet becomes difficult
Solution Approach 1:
The patent implements a feedback control system where a thickness sensor continuously measures the thickness of the electrode sheet during manufacturing, and a controller adjusts the gap between sheet forming rollers based on the measured thickness to maintain the target thickness value. This closed-loop feedback mechanism resolves the thickness control difficulty in the dry electrode process while maintaining high manufacturing efficiency.
Solution Approach 2:
The patent makes the gap between sheet forming rollers dynamically adjustable during the manufacturing process. The gap adjuster modifies the roller gap in real-time based on feedback from the thickness sensor, allowing the system to adapt to variations in material properties and maintain consistent thickness control throughout production, thereby resolving the contradiction between efficiency and precision.
2Manufacturing precision
If the gap between sheet forming rollers is adjusted to control thickness, then the thickness precision is improved, but the device complexity increases
Solution Approach 1:
The controller serves multiple functions: it receives signals from both the thickness sensor and the force sensor, processes the feedback information, and controls the gap adjuster to modify roller gap. This multi-functional control system achieves precise thickness control without requiring separate dedicated control mechanisms for each function, thereby limiting the increase in device complexity.
Solution Approach 2:
The force sensor acts as an intermediary element that measures the force applied to the sheet forming rollers and provides feedback to the controller. This intermediary measurement enables indirect control of thickness through force monitoring, adding a sensing function without requiring direct mechanical modification of the roller gap mechanism, thus limiting complexity increase.
Data Source
AI summary
Proposed is an apparatus and method for manufacturing a dry electrode sheet. The apparatus includes a material feeder supplying an electrode material, a pair of sheet forming rollers facing each other and forming an electrode sheet by pressurizing the electrode material supplied from the material feeder, a first force sensor connected to each of the sheet forming rollers and measuring a force applied to each of the sheet forming rollers, a thickness sensor measuring a thickness of the electrode sheet, a gap adjuster connected to each of the sheet forming rollers and adjusting the gap between the sheet forming rollers, and a controller controlling the gap adjuster to adjust the gap between the sheet forming rollers on the basis of a force value measured by the first force sensor so that the thickness of the electrode sheet received from the thickness sensor matches a target value.