Continuous Electrode Coating with Single-Source Dual-Side Transfer
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Solution Overview
Problem
Existing methods for manufacturing electrodes in metal-ion batteries require multiple dedicated coating sources, increasing complexity and energy consumption, and cannot simultaneously coat both sides of a current collector efficiently.
Innovation Solution
A continuous manufacturing process that uses a single ink source to coat both sides of a current collector simultaneously, transferring ink from one side to the other through rollers and drying the ink in a single oven, reducing the need for multiple coating sources and optimizing energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two dedicated coating sources are used to coat both sides of the collector simultaneously, then coating productivity is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent applies universality by using a single coating source to perform the function of coating both sides of the collector. The ink deposited on the first side is transferred to the second side through the roller mechanism, allowing one coating source to accomplish what traditionally required two separate sources, thereby reducing system complexity while maintaining simultaneous coating capability
Solution Approach 2:
The patent merges the coating operations for both sides of the collector into a single integrated process. By combining the deposition on the first side and the transfer to the second side through rollers, the system consolidates what were previously separate coating operations into one unified process, reducing the number of dedicated coating sources needed
2Productivity
If two dedicated coating sources are used to coat both sides of the collector simultaneously, then coating productivity is improved, but energy consumption increases
Solution Approach 1:
The single coating source performs dual function by coating the first side and enabling transfer to the second side through rollers. This eliminates the need for a second dedicated coating source, thereby reducing the energy consumption associated with operating multiple coating systems while maintaining simultaneous coating productivity
3Ease of manufacture
If traditional gravity-fed ink coating process is used, then manufacturing simplicity is improved, but coating speed and productivity are limited
Solution Approach 1:
The patent implements continuous action by maintaining constant movement of the collector through the coating and drying zones. The ink deposition, transfer, and drying processes occur continuously as the collector moves through the system, eliminating interruptions and maximizing coating speed while maintaining process simplicity
Solution Approach 2:
The patent applies preliminary action by depositing ink on the first side of the collector before the transfer to the second side occurs. This pre-deposition step allows the ink to be prepared and then transferred in a continuous flow, enhancing coating speed while keeping the manufacturing process straightforward
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 process simplifies the manufacturing system, reduces energy expenditure, and ensures homogeneous coating on both sides of the collector, enhancing production efficiency and reducing ink losses.
Implementation Method 1
continuous drying of the deposited ink to remove the solvent, by a drying device
Data Source
Figure 1~2
Figure 3
AI summary
This continuous manufacturing process for an electrode (2) comprises the following steps carried out simultaneously and continuously: - continuous movement of a current collector (4), said current collector having a first face (A) and a second face (B) opposite the first face (A), - continuous deposition of an ink (9) on the first face (A) of the current collector (4) from an ink reservoir (10) (9), said ink comprising at least a solvent and an active material, - continuous deposition of ink (9) on the second face (B) of the current collector (4), - continuous drying of the deposited ink (9) to remove the solvent, by a drying device (15), said deposition of ink on the second face (B) of the collector (4) being carried out by coating with ink deposited on the first face (A) of the collector (4).