Electrode Coating Thickness Measurement with Substrate Stretch Correction
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Solution Overview
Problem
Existing electrode manufacturing methods struggle to accurately calculate the coating thickness of electrode ink on substrates due to substrate stretching during conveyance, leading to inaccurate non-defective product determination.
Innovation Solution
The method involves applying electrode ink to a substrate with markings at specific intervals, measuring pre- and post-coating thicknesses, calculating length ratios between markings, and correcting position information to interpolate accurate coating thicknesses, accounting for substrate stretching during conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If radiation measurement is performed to detect coating thickness, then coating thickness can be measured, but accurate calculation is impossible when substrate stretching occurs during conveyance
Solution Approach 1:
The patent measures the substrate thickness and markings position before the coating process (pre-coating measurement) to establish a reference state. This preliminary measurement captures the substrate's original dimensions before stretching occurs during conveyance, enabling accurate coordinate transformation and coating thickness calculation even when the substrate deforms during the process.
Solution Approach 2:
The system uses the pre-coating measurement data as feedback to correct and transform the post-coating measurement coordinates. By comparing the pre-coating and post-coating markings positions, the system calculates the stretching ratio and applies coordinate transformation to accurately determine the coating thickness despite substrate deformation during conveyance.
2Productivity
If substrate is conveyed from unwinding roll to winding roll with tension, then continuous manufacturing is enabled, but substrate stretching occurs making thickness detection at the same position difficult
Solution Approach 1:
The patent introduces markings on the substrate as an intermediary reference feature. These markings serve as fixed reference points that can be detected both before and after coating. By tracking the markings' position changes, the system can calculate the stretching ratio and transform coordinates to accurately determine coating thickness despite the substrate's movement and deformation during continuous conveyance.
Solution Approach 2:
The system dynamically adjusts the coordinate transformation parameters based on the measured stretching ratio. By calculating the ratio between pre-coating and post-coating markings distances, the system adapts the measurement coordinates to account for substrate deformation, enabling accurate coating thickness measurement throughout the continuous manufacturing process.
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 calculation of coating thickness, ensuring accurate non-defective product determination and marking defective products, even under conditions of substrate stretching.
Implementation Method 1
A radiation measuring apparatus discussed in Japanese Patent Application Laid-Open No. 2011-196755 includes a radiation source and a sensor, and detects the coating thickness of an electrode substrate based on the intensity of radiation reaching the sensor from the radiation source through the electrode substrate.
Data Source
AI summary
A length L between the markings 11a measured by the pre-coating thickness measuring device 17 and a length L′ between the markings 11a measured by the post-coating thickness measuring device 18 are calculated, and a length ratio is obtained. Measurement positions of thickness data measured by the post-coating thickness measuring device 18 are corrected based on the calculated length ratio. A value at each measurement position of pre-coating thickness information on a corrected post-coating thickness interpolation line connecting measurement points of corrected post-coating thickness information obtained by correcting the measurement positions with a line segment is determined as post-coating thickness at each measurement position. A difference between the determined value and the pre-coating thickness is calculated. If it is in a predetermined range, the electrode is determined as a non-defective product.