Electrostatic Powder Coating for Battery Current Collectors
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Solution Overview
Problem
The existing battery manufacturing process using wet coating for electrode current collectors leads to environmental pollution due to evaporation of coating materials during baking and increases coating costs if these materials are recycled.
Innovation Solution
A coating device utilizing an electrostatic roller set and rod to apply powder coatings electrostatically, ensuring uniform coating thickness without evaporation of volatile substances, thereby reducing environmental pollution and coating costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wet coating is used to coat the current collector, then the coating can be applied continuously, but the coating material evaporates into the air causing environmental pollution and increasing costs
Solution Approach 1:
The patent changes the physical state of the coating material from liquid (wet coating) to powder form, and changes the coating mechanism from liquid deposition to electrostatic adsorption. This parameter change eliminates the evaporation issue while maintaining continuous coating capability, as the powder coating material is electrostatically adsorbed onto the current collector surface without requiring baking that causes evaporation
Solution Approach 2:
The patent replaces the wet coating mechanical system (liquid application + thermal baking) with an electrostatic coating system. The electrostatic roller generates electric field forces that adsorb powder coating material onto the current collector, substituting the thermal-baking-based liquid coating process with an electrostatic-based powder coating process that avoids evaporation pollution
2Reliability
If wet coating with baking is used, then the coating adheres well to the current collector, but expensive recycling equipment and large baking equipment are required
Solution Approach 1:
The patent extracts and eliminates the baking equipment from the coating system by using powder coating with electrostatic adsorption. The coating material is applied in powder form and adheres through electrostatic forces and subsequent compression, removing the need for large thermal baking equipment and associated recycling systems
Solution Approach 2:
The patent changes the coating application parameters from liquid-phase thermal deposition to solid-phase electrostatic deposition. This parameter change allows coating adhesion to be achieved through electrostatic attraction and mechanical compression rather than thermal bonding, eliminating the need for expensive baking and recycling equipment
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
The electrostatic coating device ensures the formation of coatings with uniform thickness, reduces environmental pollution by eliminating air-borne pollutants, and decreases coating costs by eliminating the need for expensive recycling and large baking equipment.
Implementation Method 1
the electrostatic roller set is at least partially rotatable and configured to electrostatically adsorb the powder
Implementation Method 2
the electrostatic rod is configured to provide electrostatic adsorption force to the powder on the electrostatic roller set, so that the powder is peeled off from the electrostatic roller set and laid on the member to be coated
Implementation Method 3
the composite assembly is configured to connect the powder laid on the member to be coated with the member to be coated to form the coating connected to the member to be coated
Implementation Method 4
the composite assembly is configured to connect the powder laid on the member to be coated with the member to be coated
Data Source
AI summary
A coating device for applying a coating to a member to be coated includes: a roller assembly including a first spool and second spool that are spaced apart, wherein the first spool is configured to release the member to be coated that is to be coated, and the second spool is configured to roll up the member to be coated after being coated with a coating; a coating assembly including an electrostatic roller set and an electrostatic rod, wherein the electrostatic roller set is at least partially rotatable and is configured to electrostatically adsorb the powder, the electrostatic rod is configured to provide electrostatic adsorption force to the powder on the electrostatic roller set; a composite assembly provided at downstream position of the coating assembly, and configured to connect the powder laid on the member to be coated with the member to be coated.