Electrode Plate Insulation Coating Control for Uniform Overlay Width
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Solution Overview
Problem
Existing technologies lack precise control over the overlay width of insulating material coated on electrode plates, leading to potential battery failures due to non-uniform insulation, which can result in short circuits and thermal runaway.
Innovation Solution
An insulation-coating overlay control system that includes an insulation coater, a width measuring means, and a controller to adjust the overlay width and non-coated part coating width within predetermined ranges or reference values using a vision camera for precise measurement and feedback control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If insulating material is coated on electrode plate without precise overlay control, then coating process is simple, but insulation uniformity deteriorates leading to short circuit risks
Solution Approach 1:
The patent implements a feedback control system where a vision camera measures the actual overlay width of the insulating material coating, and the controller adjusts the coating position based on the measured value to maintain uniformity within a predetermined range. This closed-loop feedback mechanism resolves the contradiction by providing precise control without excessive system complexity.
Solution Approach 2:
The patent replaces complex mechanical positioning systems with a vision-based measurement and control system. Instead of relying on purely mechanical methods to maintain overlay uniformity, the system uses optical measurement (vision camera) and electronic control to achieve precise overlay width control, simplifying the mechanical complexity while improving precision.
2Reliability
If overlay width is not controlled within predetermined range, then manufacturing process is simpler, but battery reliability deteriorates due to short circuit and thermal runaway risks
Solution Approach 1:
The feedback control system measures the actual overlay width and adjusts the coating process to maintain it within the predetermined range (0.1-1.0 mm). This ensures reliable insulation between positive and negative electrodes, preventing short circuits and thermal runaway, while keeping the control system complexity manageable through automated feedback rather than complex mechanical structures.
Solution Approach 2:
The patent introduces a vision camera as an intermediary measurement device between the coating process and the control system. This intermediary enables precise measurement of overlay width without direct mechanical contact or complex sensing, facilitating reliable control while minimizing system complexity.
3Measurement precision
If vision camera and feedback control are implemented, then overlay width precision is improved, but device complexity increases
Solution Approach 1:
The patent uses a vision camera (optical measurement) to replace complex mechanical measurement systems. This provides high measurement precision for overlay width while avoiding the mechanical complexity of contact-based measurement devices, resolving the contradiction between precision and complexity.
Solution Approach 2:
The vision-based measurement system is integrated into the coating process itself, allowing the system to self-measure and self-adjust the overlay width. This self-service capability improves measurement precision without requiring separate complex measurement and control systems.
Data Source
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AI summary
The present technology relates to an insulation-coating overlay control system, and the system includes: an insulation coater which coats an insulating material to allow the insulating material to cover a partial region of a coated part, on which an electrode slurry has been coated, and a non-coated part, on which the electrode slurry has not been coated, in an electrode plate, along a boundary part between the coated part and the non-coated part; an insulation-coating width measuring means which measures an overlay width, which is a width of an overlay region where the insulating material has been coated on the coated part, and a non-coated part coating width, which is a width of a region where the insulating material has been coated on the non-coated part; an insulation coater moving means which moves the insulation coater; and a controller which controls the insulation coater moving means to adjust the overlay width by comparing the measured overlay width with a predetermined overlay width setting range or an overlay width reference value. The present invention also relates to an electrode plate for a secondary battery, and an insulation-coating overlay control method.