Electrode Coating Thickness Control Using Roll Position Sensing
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Solution Overview
Problem
Conventional electrode production methods experience film thickness variation in the electrode mixture layer due to stress-induced deformation or shaft misalignment of the second roll, leading to inappropriate feedback control and unstable production.
Innovation Solution
The method involves rolling an electrode material between a first and a second roll to form a mixture coated film, attaching it to the second roll, and transporting it. A first sensor detects the surface position of the mixture coated film, and a second sensor detects the surface position of the second roll, allowing for precise detection of film thickness and adjustment of the rotation speed ratio of the third roll relative to the second roll based on this detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the second roll is used for both rolling and compression bonding, then the production process is integrated and efficient, but the roll experiences very large stress causing deformation or shaft misalignment
Solution Approach 1:
The patent divides the second roll into two independent components: a roll body for rolling and a compression roll for bonding. This segmentation allows each component to be optimized for its specific function, with the compression roll being replaceable and adjustable, thereby preventing stress-induced deformation from affecting the rolling precision.
Solution Approach 2:
The compression roll is designed to be adjustable and replaceable, allowing dynamic modification of the compression force and roll characteristics. This enables the system to adapt to different production requirements while maintaining stable film thickness through precise control of compression parameters.
2Manufacturing precision
If feedback control is implemented based on film thickness detection, then production stability should improve, but deformation of the second roll causes false detection and inappropriate control
Solution Approach 1:
A sensor is introduced as an intermediary detection device positioned to measure film thickness without being affected by roll deformation. The sensor provides accurate real-time feedback on actual film thickness, enabling the control system to compensate for variations and maintain precise thickness control despite mechanical issues with the rolls.
3Ease of operation
If the second roll deforms apart from the sensor, then the film thickness is detected as decreased, but the actual film thickness is appropriate, leading to incorrect control adjustments
Solution Approach 1:
The system implements a feedback control mechanism where the sensor continuously monitors actual film thickness and the control system adjusts rolling and compression parameters in real-time based on this accurate feedback. This closed-loop control compensates for any detection errors and maintains precise film thickness despite roll deformation.
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 approach enables precise detection of film thickness and execution of feedback control, resulting in stable production of electrodes with a desired film thickness, reducing variations and improving the quality of the electrode mixture layer.
Implementation Method 1
detecting the surface position of the mixture coated film attached to the second roll by a first sensor; detecting the surface position of the second roll by a second sensor; detecting the film thickness of the mixture coated film based on the difference between the detection result of the first sensor and the detection result of the second sensor
Implementation Method 2
rolling an electrode material between a rotating first roll and a rotating second roll to form a mixture coated film
Implementation Method 3
passing the mixture coated film and the electrode current collector between the second roll and the third roll to compressedly bond the mixture coated film to the surface of the electrode current collector
Data Source
AI summary
According to the present disclosure, an electrode having an electrode mixture layer with a desired film thickness can be stably produced. A producing method disclosed herein includes detecting the surface position of a mixture coated film by a first sensor; detecting the surface position of a second roll by a second sensor; detecting the film thickness of the mixture coated film based on detection results of the first sensor and the second sensor; and adjusting a relatively rotation speed of a third roll based on the film thickness. And, the detected positions of the first sensor and the second sensor in a circumferential direction of the second roll are substantially identical. Due to this method, the change in the film thickness of the electrode mixed layer of produced electrode can be suppressed.