Insulation Overlay Evaluation via Simulated Coating Thickness
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Solution Overview
Problem
Evaluating the insulation of an overlay part in lithium secondary batteries without measuring the thickness of the insulation coating layer is challenging due to the difficulty in measuring the insulating performance, which is typically proportional to the thickness, and the need for new equipment, especially since part of the insulation coating liquid permeates into the electrode mixture layer.
Innovation Solution
A method that involves simulating the overlay part and pure insulation coating layer by applying and drying insulation coating liquid, collecting data on gap lengths and thicknesses, and generating relation formulas to calculate the capacity of the overlay part based on the thickness of the pure insulation coating layer, allowing for insulation evaluation without introducing new equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the thickness of the insulation coating layer in the overlay part is measured to evaluate insulation, then the insulating performance can be assessed, but new equipment must be introduced which increases device complexity and cost
Solution Approach 1:
The patent creates a simulated overlay part that replicates the key characteristics of the actual overlay part. By measuring the thickness of the insulation coating layer in this simulated copy structure, the insulating performance of the actual overlay part can be evaluated without requiring complex new measurement equipment. The simulated structure serves as a simplified model that captures the essential measurement needs.
Solution Approach 2:
The patent introduces a simulated overlay part as an intermediary between the actual overlay part and the measurement process. This simulated structure acts as a mediator that can be measured using existing equipment, while still providing information about the insulation performance of the actual component. The intermediary translates the measurement problem into a form that existing tools can handle.
2Measurement precision
If the thickness of the insulation coating layer in the overlay part is measured to evaluate insulation, then the insulating performance can be assessed, but the measurement process becomes time-consuming and costly
Solution Approach 1:
By creating a simulated overlay part that can be measured with existing equipment, the patent eliminates the need for time-consuming and costly new measurement systems. The simulated structure allows for rapid assessment using standard measurement tools already available in the manufacturing process, significantly reducing measurement time and cost.
3Reliability
If the insulation coating liquid is applied on the electrode mixture layer to form the overlay part, then the insulating performance is improved, but the insulation evaluation becomes difficult because the coating liquid permeates into the electrode mixture layer
Solution Approach 1:
The patent separates the measurement problem from the actual complex overlay part by creating a simulated version. The simulated overlay part isolates the insulation coating layer measurement from the complications of the electrode mixture layer permeation, allowing for clear distinction between the coating layer thickness and the underlying structure. This segmentation enables accurate measurement without the interference of permeation effects.
Solution Approach 2:
The simulated overlay part replicates the essential structure needed for measurement while eliminating the complicating factors of the actual overlay part. By measuring the simulated copy, the patent avoids the measurement difficulties caused by coating liquid permeation into the electrode mixture layer, as the simulated structure provides a clear measurement target.
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
Enables accurate evaluation of the insulation of the overlay part by measuring the thickness of the pure insulation coating layer, reflecting the insulating performance of both the coating layer and the material permeated into the electrode mixture layer, thus avoiding the need for new equipment and ensuring reliable insulation assessment.
Implementation Method 1
applying and drying insulation coating liquid on the electrode mixture layer
Implementation Method 2
part of the insulation coating liquid is permeated into pores of the electrode mixture layer
Data Source
AI summary
A method for evaluating insulation includes applying and drying an insulation coating liquid on a simulated overlay part, and collecting first data about a first length of a first gap of a first applicator, a first thickness which has been increased by the insulation coating liquid, and a capacity of the simulated overlay part; applying and drying the insulation coating liquid on a current collector for a simulated pure insulation coating layer, and collecting second data about a second length of a second gap of a second applicator and a second thickness of the pure insulation coating layer; generating a relation between the second thickness and the capacity; measuring a thickness of a pure insulation coating layer of an electrode for evaluation; and determining a capacity of an overlay part of the electrode for evaluation from the measured thickness using the generated relation.