Microporous Battery Separator Roll with Printed Optical End Marker
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Solution Overview
Problem
Conventional indicator tapes used in lithium-ion battery production leave impressions on the microporous film, affecting the surface shape and quality of the separator material, and reducing the thickness of the tape does not eliminate this issue, while also being costly.
Innovation Solution
A colored or character-printed indicator part is applied near the end of the original roll during the slitting step, using existing printing equipment in the production line, to serve as a detection marker for the end of the separator material without altering the surface shape or quality of the microporous film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an indicator tape is attached onto the microporous film to detect the end of the separator material, then the detection function is achieved, but an impression is pressed onto the microporous film causing surface deformation and quality deterioration
Solution Approach 1:
The patent replaces the physical indicator tape with a virtual marker created by printing a pattern or character onto the microporous film. This printed marker serves as a copy or representation of the traditional tape indicator, providing the same detection function through optical means rather than physical contact, thereby eliminating surface impressions while maintaining detection capability
Solution Approach 2:
The patent substitutes the mechanical indicator tape system with an optical printing and detection system. Instead of using a physical tape that makes contact with the film and causes impressions, the invention uses printed patterns that can be detected optically, replacing mechanical indication with optical detection to eliminate the harmful mechanical interaction
2Manufacturing precision
If the thickness of the indicator tape is reduced to minimize impressions, then the surface impact is reduced, but the cost increases significantly and the tape becomes ultra-thin and difficult to handle
Solution Approach 1:
The patent eliminates the need for physical indicator tapes by using printed markers on the film itself. This copying approach uses the film's existing surface as the indicator carrier, removing the separate tape component entirely and its associated cost and handling issues
Solution Approach 2:
The patent extracts the indicator function from the separate physical tape and integrates it directly into the microporous film through printing. This separation of the indicator function from the tape substrate eliminates the need for specialized ultra-thin tapes, using instead standard printing techniques on existing film
3Manufacturing precision
If a printed indicator part is used instead of an indicator tape, then the surface quality of the microporous film is maintained without impressions, but additional printing equipment or process steps are required
Solution Approach 1:
The patent merges the indicator marking function with the existing slitting process by integrating a printing unit into the slitting line. This combination allows the indicator to be printed during the normal production flow without requiring separate marking equipment or additional standalone process steps
Solution Approach 2:
The printing unit serves multiple functions: it creates the end-of-material indicator marker and can potentially provide other marking or identification functions. This multi-functionality reduces the need for dedicated single-purpose equipment, offsetting the added complexity with versatile utility
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 solution allows for precise detection of the end of the microporous film without impressions, improving the quality and reducing production costs by eliminating the need for a physical indicator tape, while maintaining stable operation of the battery production line.
Implementation Method 1
a sensor that senses an optical characteristic of the indicator part
Data Source
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AI summary
An object of the invention is to provide a display means with which no unevenness is caused on a surface of a separator material in a microporous film roll for a battery separator. Microporous film roll (1) for the battery separator according to the invention has indicator part (18) different in optical characteristics therefrom in microporous film (3) for the battery separator. Moreover, a method for producing microporous film roll (1) for the battery separator according to the invention has features of providing indicator part (18) different in light shieldability or light reflectivity therefrom in microporous film (3) for the battery separator.