Electrode Insulation Coating Overlay Control for Uniform Width
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Solution Overview
Problem
Existing secondary battery manufacturing processes lack precise control over the overlay width of insulating material coatings, leading to potential battery failures due to non-uniform insulation, which can result in short circuits and thermal runaway conditions.
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 by comparing measured values with predetermined settings, using a vision camera to sense color, contrast, and chroma for precise 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 and fast, but overlay width becomes non-uniform leading to short circuits and thermal runaway
Solution Approach 1:
The patent applies preliminary action by measuring the overlay width of the insulating material coating before it causes safety issues. The coating width measuring means captures images and calculates overlay width to determine whether it falls within the predetermined range, enabling proactive adjustment before defects occur in the battery assembly process
Solution Approach 2:
The patent implements feedback control through the controller that receives overlay width measurements, compares them against predetermined ranges, and automatically adjusts the insulation coater positioning. This closed-loop feedback system ensures continuous maintenance of uniform overlay width without manual intervention
2Reliability
If overlay width is not controlled within predetermined range, then coating process is simple, but battery safety decreases due to short circuit risks
Solution Approach 1:
The patent replaces manual mechanical inspection and adjustment with an automated optical measurement system. The coating width measuring means uses image capture and processing to automatically measure overlay width, substituting mechanical measurement methods with optical fields to achieve higher precision and reliability in safety control
Solution Approach 2:
The patent controls battery safety by dynamically adjusting the overlay width parameter within a predetermined range. The system modifies the coating width parameter based on measured values and feedback control, ensuring the insulating material consistently covers the boundary between coated and non-coated parts with appropriate margin
3Manufacturing precision
If insulation coater positioning is not adjusted precisely, then coating operation is simple and fast, but overlay width varies along electrode plate length
Solution Approach 1:
The patent enables self-service operation where the insulation coater automatically adjusts its own positioning based on feedback from the measurement system. The controller autonomously controls the positioning of the insulation coater to maintain consistent overlay width along the entire length of the electrode plate without requiring manual intervention at each position
Data Source
AI summary
An insulation-coating overlay control system, an electrode plate for a secondary battery, and an insulation-coating overlay control method are provided. The system includes an insulation coater configured to coat an insulating material to allow the insulating material to cover a partial region of a coated part and a non-coated part in an electrode plate along a boundary part. The coated part has an electrode slurry coated thereon and the non-coated part does not have the electrode slurry coated thereon. An insulation-coating width measuring means is configured to measure an overlay width. An insulation coater moving means is configured to move the insulation coater and a controller is configured to control 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.