Battery Electrode Coating Speckle Imaging for Inline Moisture Control
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Solution Overview
Problem
Current manufacturing processes for battery electrodes struggle with maintaining coating uniformity, particularly in terms of residual moisture, thickness, and surface roughness, leading to high reject rates and inferior battery cell quality due to the lack of effective inline monitoring and the need for costly, complex sensor systems.
Innovation Solution
An electromagnetic radiation-based method is employed to determine coating parameters such as residual moisture, layer thickness, and roughness by generating a speckle pattern, which is analyzed using a camera and artificial neural networks to adjust production processes in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If intensive overdrying process is employed to ensure residual moisture content remains below maximum value, then residual moisture control is improved, but energy consumption increases considerably
Solution Approach 1:
The patent applies preliminary action by performing inline monitoring of residual moisture during the drying process using electromagnetic radiation and dielectric spectroscopy. This allows the drying process to be optimized in real-time, applying energy only when and where needed to achieve target moisture levels, rather than using intensive overdrying for all cases.
Solution Approach 2:
The patent implements feedback control by continuously measuring residual moisture content during the drying process using electromagnetic radiation transmission and dielectric spectroscopy. The measured values are fed back to control the drying process, allowing dynamic adjustment of energy input to maintain moisture levels within specifications while minimizing energy consumption.
2Measurement precision
If multiple different sensor types are used for inline monitoring of coating parameters, then measurement capability is improved, but system cost and complexity increase
Solution Approach 1:
The patent applies universality by using electromagnetic radiation in multiple frequency ranges (microwave, millimeter wave, terahertz) to simultaneously measure multiple coating parameters including residual moisture content, layer thickness, and surface roughness. This multi-functional approach replaces the need for multiple separate sensor systems with a single integrated electromagnetic radiation-based measurement system.
Solution Approach 2:
The patent utilizes parameter changes by measuring coating properties across different electromagnetic radiation frequencies and wavelengths. By analyzing how the coating interacts with electromagnetic radiation at various frequencies (transmission, reflection, absorption characteristics), the system extracts multiple parameters simultaneously, reducing the need for multiple specialized sensors.
3Reliability
If conventional sensor systems are used for inline monitoring, then some parameters can be monitored, but comprehensive coating quality monitoring remains insufficient leading to high reject rates
Solution Approach 1:
The patent applies preliminary action by performing comprehensive inline monitoring of multiple coating parameters (residual moisture, layer thickness, surface roughness, homogeneity) during the manufacturing process. This early detection capability allows for immediate corrective actions before defective products are completed, significantly reducing reject rates compared to conventional post-production inspection methods.
Solution Approach 2:
The patent implements comprehensive feedback control by continuously monitoring multiple coating quality parameters simultaneously using electromagnetic radiation techniques. The real-time measurement data provides feedback to control the coating and drying processes, enabling dynamic adjustments to maintain quality specifications and prevent production of defective battery cells.
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
Enables inline monitoring of coating quality, reducing reject rates and improving electrode quality by allowing for immediate corrective actions during the manufacturing process, thus enhancing the efficiency and effectiveness of battery production.
Implementation Method 1
electromagnetic radiation IRR is applied using an EM source to heat a specified region of the coating
Implementation Method 2
the reflected radiation field IRR_REFL exhibits an interference pattern formed as a speckle pattern SPECK
Data Source
Figure 1
Figure 2
AI summary
The invention relates to the determination of characteristic parameters of a battery electrode coating, in particular residual moisture and/or coating thickness, during the manufacturing of the battery electrode. For this purpose, electromagnetic radiation (IRR) is applied to the coating for drying, generating a reflected radiation field characterized by a speckle interference pattern. The reflected radiation field, and thus the characteristic speckle pattern, is recorded with a camera. The resulting images allow the coating parameters to be derived from the respective speckle pattern depicted.