Electrically Heated Rollers With Zoned Temperature Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing roller systems face challenges in maintaining precise temperature control, leading to thickness variations in products like films and electrochemical cell components due to thermal expansion, which can result in defective cell production.
Innovation Solution
Integration of electrical heating elements within the roller, along with temperature sensors and a control circuit, allows for precise temperature regulation across zones, ensuring uniform thickness and properties of the film, using resistive or inductive heating elements and active cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional fluid circulation systems are used for temperature control, then temperature regulation is achieved, but device complexity increases and temperature uniformity deteriorates
Solution Approach 1:
The patent replaces the mechanical fluid circulation system with an electrical heating element system. Instead of using pumps, pipes, and fluid circulation mechanisms, the invention uses electrical heating elements that can be directly embedded in the roller structure to provide heat where needed, eliminating the complexity of fluid passages while achieving better temperature uniformity.
Solution Approach 2:
The patent divides the roller into multiple heating zones with independently controllable heating elements. Each zone can be heated to the specific temperature required for that particular section, allowing precise local temperature control and ensuring uniform temperature distribution across the entire roller surface.
2Temperature
If fluid circulation is used for heating, then temperature control is achieved, but energy loss increases due to heat loss in fluid passages
Solution Approach 1:
The patent eliminates the fluid circulation system and replaces it with direct electrical heating elements. This substitution removes the intermediate heat transfer medium (fluid) and its associated heat losses through pipes and passages, allowing electrical energy to be converted directly to heat at the precise location where it is needed, thereby minimizing energy loss.
3Manufacturing precision
If conventional rollers are used, then basic temperature control is achieved, but manufacturing precision deteriorates due to thermal expansion
Solution Approach 1:
The patent implements multiple independently controlled heating zones along the roller length. Each zone can be precisely controlled to maintain the exact temperature required, compensating for thermal expansion effects in different sections of the roller and ensuring uniform film thickness throughout the manufacturing process.
Solution Approach 2:
The patent incorporates temperature sensors that continuously monitor the roller temperature and provide feedback to the control system. This feedback mechanism allows real-time adjustment of the heating elements to maintain precise temperature control, preventing thermal expansion from affecting manufacturing precision.
4Temperature
If fluid circulation systems are used, then heating is achieved, but productivity decreases due to delays in changing rollers
Solution Approach 1:
The patent replaces the complex fluid circulation infrastructure with self-contained electrical heating elements integrated into the roller. This simplification reduces the time required to install and configure new rollers, as electrical elements can be quickly connected without the need to set up fluid passages, pumps, and circulation systems, thereby improving productivity.
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 solution maintains a consistent temperature within the roller, reducing thermal expansion effects and achieving uniform film thickness with accuracy, enabling the production of high-quality electrochemical cells by ensuring precise temperature control throughout the roller.
Implementation Method 1
the one or more electrical heating elements are resistive heating elements
Implementation Method 2
the one or more electrical heating elements are inductive heating elements
Implementation Method 3
thermal expansion associated with roller materials causes changes in the roller size
Data Source
AI summary
Methods and systems for electrically heating and cooling rollers is described. A system may include one or more rollers comprising one or more electrical heating elements and one or more air channels. The one or more electrical heating elements may integrated to a power source and control circuit through an electrical contact on at least one end of the roller. The control circuit may additionally receive input from one or more temperature sensors.