Electrode Coating Alignment Using Detection-Guided Liquid Discharge
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Solution Overview
Problem
Existing electrode manufacturing processes face challenges in accurately controlling the liquid discharge operation to align with changes in the positions and patterns of electrode composition layer portions on the current collector, leading to potential defects such as short circuits or inefficient use of the current collector area.
Innovation Solution
An electrode printing apparatus that includes a detector to detect changes in the electrode composition layer portions and a controller to adjust the liquid discharge head's discharge conditions based on combined detection information, ensuring precise alignment and coverage of the resin or inorganic layers on the electrode substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the liquid discharge operation is performed without real-time detection and adjustment, then the device complexity is reduced, but the manufacturing precision of resin or inorganic layer alignment deteriorates
Solution Approach 1:
The detector captures images of the electrode composition layer portions before the liquid discharge operation, and the controller pre-calculates the discharge positions based on detected positional deviations. This preliminary detection and calculation enable accurate alignment without requiring complex real-time adjustment mechanisms during discharge.
Solution Approach 2:
The system uses detection information from the detector to provide feedback to the controller, which adjusts the liquid discharge positions accordingly. This feedback loop ensures that positional deviations are corrected, maintaining high manufacturing precision while using a relatively simple adjustment mechanism.
2Productivity
If the liquid discharge operation is performed without real-time adjustment, then the device complexity is reduced, but the productivity deteriorates due to potential defects and rework
Solution Approach 1:
By detecting the positions of electrode composition layer portions before liquid discharge and pre-calculating adjusted discharge positions, the system prevents defects before they occur. This eliminates the need for time-consuming rework and inspection, thereby improving productivity without requiring complex real-time adjustment systems.
Solution Approach 2:
The feedback mechanism uses detection information to adjust discharge positions, ensuring accurate formation of resin or inorganic layers on all electrode composition layer portions. This prevents short circuits and other defects, improving manufacturing efficiency while maintaining a relatively simple system architecture.
3Reliability
If the liquid discharge operation is performed without position adjustment, then the device complexity is reduced, but the reliability deteriorates due to potential short circuits
Solution Approach 1:
The detector captures images of the electrode composition layer portions before liquid discharge, and the controller pre-calculates the discharge positions based on detected positional deviations. This preliminary adjustment ensures that resin or inorganic layers are accurately formed on all electrode composition layer portions, preventing short circuits and improving reliability without requiring complex real-time adjustment mechanisms.
Solution Approach 2:
The system uses detection information to provide feedback to the controller, which adjusts liquid discharge positions to ensure accurate coverage of electrode composition layer portions. This feedback mechanism prevents defects such as short circuits, enhancing reliability while maintaining a relatively simple system design.
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
The apparatus effectively controls the liquid discharge to ensure accurate formation of resin or inorganic layers, preventing defects like short circuits and optimizing the use of the current collector area, thereby enhancing the reliability and efficiency of the electrode manufacturing process.
Implementation Method 1
a liquid discharge head (5) to discharge the liquid composition onto the electrode composition layer portions (2a)
Implementation Method 2
a light source (6) to irradiate each liquid composition layer portion formed on the electrode substrate with light, to cure the liquid composition layer portion into the resin layer portion (2b)
Implementation Method 3
a heater (7) to heat the resin precursor layer portions formed by discharging the liquid composition for forming the resin layer portions on the electrode substrate
Data Source
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AI summary
An electrode manufacturing apparatus according to one aspect of the present disclosure is configured to discharge a liquid to form a resin layer or an inorganic layer on an electrode substrate which is being conveyed in a predetermined direction. The electrode manufacturing apparatus includes a detector, a liquid discharger provided downstream of the detector in the predetermined direction and configured to discharge the liquid to form the resin layer or the inorganic layer, and a controller configured to control a discharge condition of the liquid discharger. Points where a property varies are present on the electrode substrate along a direction intersecting the predetermined direction. The detector outputs pieces of detection information obtained by detecting one of the points in time series, and the controller controls the discharge condition of the liquid discharger based on combined detection information obtained by combining the pieces of detection information.