Microwave Drying Device for Separator Film
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Solution Overview
Problem
Conventional drying processes for separator films in lithium-ion batteries are time-consuming, requiring three days of rest followed by an 8-hour vacuum oven process at limited temperatures, making them inefficient and space-intensive.
Innovation Solution
A microwave drying device with a processing box that uses microwaves to heat and dry separator films uniformly and quickly, featuring a wave traveling channel and suction modules to enhance drying efficacy and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional drying process (resting in drying chamber + vacuum oven baking) is used, then separator film can be sufficiently dried, but drying time becomes extremely long (3 days + 8 hours)
Solution Approach 1:
The patent replaces the conventional thermal conduction-based drying system (vacuum oven heating from outside) with a microwave-based drying system that uses electromagnetic radiation to heat the separator film directly from within, achieving rapid and uniform drying without the time-consuming conventional process
Solution Approach 2:
The patent changes the heating parameter from external thermal conduction (vacuum oven) to internal microwave heating, fundamentally altering the drying mechanism to achieve both speed and uniformity. The microwave frequency and power parameters are optimized to ensure sufficient drying while dramatically reducing time
2Productivity
If vacuum oven temperature is increased to shorten drying time, then drying speed improves, but separator film cannot resist high temperature
Solution Approach 1:
The patent substitutes the external thermal heating system (vacuum oven) with a microwave electromagnetic heating system, allowing the separator film to be dried at lower temperatures while achieving faster drying speeds through internal heating mechanisms that do not rely on external temperature escalation
Solution Approach 2:
The separator film dries itself through internal microwave heating, where the microwave energy is absorbed by the separator film material and converted to heat within the film structure, eliminating the need for high external temperatures that would damage the film
3Manufacturing precision
If conventional drying chamber and vacuum oven are used, then separator film can be dried, but device size becomes enormous and occupies too much space
Solution Approach 1:
The patent merges the drying chamber and heating system into a compact integrated microwave drying device, combining the processing space, microwave emitting modules, and suction modules into a single compact unit that replaces the separate, space-consuming drying chamber and vacuum oven
Solution Approach 2:
The patent transitions from a large-volume conventional drying chamber to a compact microwave cavity structure, utilizing the three-dimensional microwave field distribution to achieve effective drying in a much smaller volume, fundamentally changing the spatial requirements of the drying process
4Productivity
If microwave emitting modules are added to achieve uniform drying, then drying efficiency improves, but device complexity increases
Solution Approach 1:
The patent divides the microwave drying system into multiple emitting modules distributed within the processing box, with each module responsible for a specific zone. This segmentation allows uniform drying across the separator film while maintaining modular simplicity in the overall structure
Solution Approach 2:
The microwave emitting modules serve multiple functions: they provide the heating source, create the microwave field distribution pattern, and work in conjunction with the suction modules to achieve both drying and moisture removal. This multi-functionality reduces the need for separate components, simplifying the overall device structure
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
Significantly reduces drying time, saves space, and improves drying efficiency by using microwaves to penetrate and dry both outer and inner layers of the film, while also reducing material and production costs through a more compact design.
Implementation Method 1
the at least one microwave emitting module is mounted on the external mounting wall of the processing box and emits microwaves toward the wave travelling channel
Implementation Method 2
uses microwaves to heat up and dry a separator film uniformly and promptly
Implementation Method 3
the at least one suction module connects to the at least one suction space
Data Source
AI summary
A microwave drying device has a processing box. Two mounting openings are formed on an external mounting wall of the processing box. Two suction partitions are mounted in the processing box and divide an inner space of the processing box into a microwave drying space and two suction spaces. The microwave drying space is located between and connects to the two suction spaces. Multiple channel partitions are mounted in the microwave drying space to form a meandering wave travelling channel. Two opposite ends of the wave travelling channel connect to the two mounting openings respectively. Two microwave emitting modules are mounted on the external mounting wall and emit microwaves toward the two mounting openings respectively. Multiple openings are formed in the processing box such that a film can travel through the processing box. Therefore, drying speed is greatly increased, and the drying device is more compact.