Electrode Coating Quality Detection Using Millimeter Wave Profiles

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Solution Overview

Problem

The coating process in battery manufacturing relies heavily on manual quality control, resulting in low accuracy, slow adjustment speed, and high material waste, affecting production efficiency and corporate profits, with defects judged subjectively.

Innovation Solution

A coating quality detection method that calculates weight averages and extreme differences of edge and center zones in a coating region using millimeter wave data to determine abnormal coatings, preventing defective outputs and ensuring battery cell quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual quality control is used for coating detection, then operation simplicity is maintained, but measurement precision and manufacturing precision deteriorate

Engineering Contradiction:

Improveoperation simplicityVSAvoiddetection accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces manual visual inspection with an automated optical detection system that captures images of the coating surface and uses image processing algorithms to objectively measure coating quality parameters, thereby improving measurement precision while maintaining ease of operation through automation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an intermediary detection system consisting of imaging devices and image processing software that acts as a mediator between the coating process and quality assessment, enabling precise measurement without requiring direct manual intervention

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If manual quality control is used for coating detection, then device complexity is reduced, but manufacturing precision deteriorates

Engineering Contradiction:

Improvesystem simplicityVSAvoidcoating quality

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces simple manual inspection with a sophisticated automated optical detection system that uses image capture and processing algorithms to achieve high manufacturing precision, accepting increased device complexity as necessary for quality improvement

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If subjective judgment is used for defect detection, then ease of operation is maintained, but measurement precision deteriorates

Engineering Contradiction:

Improvedetection simplicityVSAvoiddefect detection accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces subjective human judgment with objective image processing algorithms that automatically analyze coating images, identify defects, and quantify quality parameters, eliminating subjectivity and improving measurement precision while maintaining operational simplicity through automation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a digital copy of the coating surface through imaging and uses this copy for automated analysis, allowing precise defect detection without requiring direct subjective assessment of the physical surface

Inventive Principle:

Principle #26Copying

4Measurement precision

If automated detection is implemented, then measurement precision improves, but device complexity increases

Engineering Contradiction:

Improvedetection accuracyVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent implements automated optical detection with image processing capabilities to achieve high measurement precision, accepting increased device complexity as a necessary trade-off for improved detection accuracy and quality control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method provides accurate and efficient coating quality detection, preventing abnormal coatings from affecting subsequent production processes and ensuring the quality of battery cells by quickly identifying and addressing defects.

Implementation Method 1

detecting a coating region on the membrane to obtain millimeter wave data

Methodology Applied

Scientific EffectMillimeter wave detection: Microwave Radiation

Data Source

PatentUS20250012692A1Coating quality detection method, detection apparatus, and detection system, and storage medium

Publication Date: 2025.01.09 JIANGSU CONTEMPORARY AMPEREX TECH LTD

AI summary

A coating quality detection method relates to the field of coating technologies. The detection method includes the following steps: detecting a coating region on a membrane to obtain millimeter wave data; obtaining edge zero lines on two sides of the coating region, and setting a primary zone of the coating region based on the edge zero lines on the two sides; calculating a weight average of the edge zones and a weight average of the center zone; calculating a first extreme difference a between the weight average of the edge zones and the weight average of the center zone; and/or calculating a weight extreme difference b of the primary zone. The detection method can ensure the coating quality of the surface of the electrode plate, and thus ensure the quality of the cell.