Low-Expansion Coating Roll for Uniform Electrode Film Thickness
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Solution Overview
Problem
Conventional coating devices for electrode plates in secondary batteries suffer from non-uniform film thickness due to thermal expansion, leading to suboptimal coating quality.
Innovation Solution
The coating device incorporates a roll and coater with components made of low expansion materials, having a linear expansion coefficient between 0 and 6.0×10−6 1/K, to minimize thermal deformation and maintain uniform film thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional materials are used for the roll, then the device structure is simple and easy to manufacture, but the film thickness becomes non-uniform due to thermal expansion
Solution Approach 1:
The patent changes the material parameter (linear expansion coefficient) of the roll from conventional materials to low expansion materials, specifically selecting materials with a linear expansion coefficient in the range of 0 to 6.0×10−6 1/K. This parameter change directly addresses the thermal expansion issue that causes film thickness non-uniformity, while maintaining the overall device structure simplicity.
Solution Approach 2:
The patent employs composite material selection by combining low expansion materials with other device components. The roll is specifically made from low expansion materials such as Invar, Fe-Pd alloys, or Fe-Ni-Co alloys, while other parts of the coating device can use conventional materials, creating a targeted composite material approach that solves the thermal expansion problem without requiring the entire device to be made from specialized materials.
2Manufacturing precision
If low expansion materials are used for the roll, then the coating quality improves with uniform film thickness, but the material cost and selection complexity increases
Solution Approach 1:
The patent specifies a precise parameter range for the linear expansion coefficient (0 to 6.0×10−6 1/K) to ensure coating quality improvement. This parameter-based selection provides clear manufacturing criteria that balance coating quality requirements with material availability, making it easier to select appropriate low expansion materials from existing options.
Solution Approach 2:
The patent applies low expansion materials specifically to the roll component where thermal stability is most critical for maintaining coating quality. This localized application of specialized materials optimizes coating precision where needed while avoiding the use of expensive or difficult-to-obtain materials in other less critical device components, thereby improving ease of manufacture.
3Stability of the object's composition
If the roll material has high thermal expansion coefficient, then the device is easier to manufacture with common materials, but the coating gap becomes unstable during operation
Solution Approach 1:
The patent changes the thermal expansion parameter of the roll material to a specific range (0 to 6.0×10−6 1/K) that ensures coating gap stability during operation. This parameter specification provides clear manufacturing guidance while achieving the desired stability, balancing material specification requirements with operational performance.
Solution Approach 2:
Instead of trying to compensate for thermal expansion through complex control systems or adjustable mechanisms, the patent inverts the approach by selecting a material whose inherent low thermal expansion property passively maintains coating gap stability. This material-based solution is simpler than active compensation systems.
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 use of low expansion materials stabilizes the coating gap, ensuring a uniform film thickness and improved coating quality, particularly for electrode plates in secondary batteries.
Implementation Method 1
at least a portion of the roll to be in contact with the material to be coated or at least a portion of the roll onto which a coating material is applied is formed of a low expansion material that has a linear expansion coefficient in the range from 0 [1/K] to 6.0×10−6 [1/K] inclusive
Data Source
AI summary
A coating device includes a roll that conveys a material to be coated or onto which a coating material is applied, and a coater used to apply a coating material onto the material to be coated or onto the roll. At least a portion of the roll to be in contact with a material to be coated or at least a portion of the roll onto which a coating material is applied is formed of a low expansion material that has a linear expansion coefficient in the range from 0 [1/K] to 6.0×10−6 [1/K] inclusive.