Hybrid Laser Electrode Drying for Edge Delamination Control
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Solution Overview
Problem
Conventional drying processes for battery electrode coatings, such as those used in lithium-ion and sodium-ion batteries, are energy-inefficient and can cause excess heating and delamination at the edges of the coatings due to uneven laser irradiation.
Innovation Solution
A hybrid laser drying system using a diverging laser beam for the interior coating area and a multi-beam laser diode array for the edges, with adjustable intensity distribution, to ensure even drying and prevent over-heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If conventional convection ovens or infrared lamps are used for drying, then drying capability is achieved, but energy consumption is excessively high
Solution Approach 1:
The patent replaces conventional thermal drying systems (convection ovens and infrared lamps) with a laser-based drying system. The laser beam directly heats and evaporates the solvent in the coating material, eliminating the need for large-scale thermal fields and significantly reducing energy consumption while maintaining effective drying capability.
2Use of energy by stationary object
If laser drying is used to reduce energy consumption, then energy efficiency improves, but excess heating at coating edges occurs causing delamination
Solution Approach 1:
The patent applies local quality by differentiating the drying approach for different regions of the coating. The laser beam parameters (such as power, scanning speed, or pulse duration) are adjusted based on the local characteristics of the coating material and substrate in different areas, enabling precise control of heating to prevent edge delamination while maintaining overall drying efficiency.
Solution Approach 2:
The patent employs dynamic control of the laser drying process, where parameters such as laser power, scanning speed, or beam positioning are adjusted in real-time based on feedback from sensors monitoring the drying state. This dynamic adaptation allows the system to respond to varying local conditions and prevent harmful overheating while maintaining energy efficiency.
3Ease of operation
If uniform laser irradiation is applied to the coating, then drying simplicity is maintained, but edge areas dry too quickly causing quality defects
Solution Approach 1:
The patent implements local quality control by applying different laser irradiation parameters to different regions of the coating. The system accounts for the fact that edge areas have different thermal characteristics and solvent content compared to the center, and adjusts the laser parameters accordingly to achieve uniform drying across the entire coating area.
Solution Approach 2:
The patent incorporates feedback mechanisms that monitor the drying process in real-time, detecting variations in solvent evaporation rates across different coating regions. This feedback information is used to dynamically adjust laser parameters, ensuring that edge areas receive appropriate heating without over-drying, thereby maintaining manufacturing precision.
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 system achieves energy-efficient drying with reduced energy consumption, up to 10-50% of conventional methods, while preventing delamination by tailoring the spatial intensity distribution.
Implementation Method 1
Laser drying is as an alternative to conventional drying of battery electrode coatings using convection ovens or infrared lamp drying
Implementation Method 2
The coating apparatus subjects the slurry to a drying process that removes the solvent
Data Source
AI summary
A system for drying a battery electrode coating includes two laser diode arrays and a laser module. Each laser diode array emits multi-beam laser radiation to an edge region including a respective edge of a coating lane deposited on a metal foil. The laser module emits a diverging laser beam to an interior area of the coating lane between the two edges. The intensity distribution of the diverging laser beam at the coating lane spans a gap in the widthwise dimension between respective intensity distributions of the multi-beam laser radiation from the two laser diode arrays. The use of laser diode arrays to perform the edge drying allows for tailoring the intensity distribution of the combined laser irradiation to dry the coating lane without over-drying and delaminating the edges. The use of a single, diverging laser beam in the interior area allows for optimizing affordability and energy efficiency.