Powder Hopper Sensor Control for Uniform Dry Electrode Coating
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Solution Overview
Problem
Conventional electrode manufacturing processes using solvents are costly, environmentally impactful, and pose health risks due to toxic chemicals, while dry processes require consistent powder application to achieve tight tolerances.
Innovation Solution
A system comprising powder hoppers with sensors and feeder hoppers that monitor powder levels and weights to ensure consistent powder supply to calendering rollers, ensuring uniform powder application and reducing the need for solvent-based drying processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wet process with solvents is used to manufacture electrodes, then the manufacturing process is established and electrodes can be produced, but the process becomes expensive, environmentally impactful, and dangerous due to toxic solvent chemicals
Solution Approach 1:
The patent changes the fundamental parameter of the manufacturing process from wet (solvent-based) to dry (solvent-free). This parameter change eliminates toxic chemicals entirely while maintaining electrode production capability through alternative mechanisms (dry powder application and calendering).
Solution Approach 2:
The patent extracts and removes the harmful solvent component from the manufacturing process entirely. By taking out the solvent, the process eliminates toxicity, environmental impact, and safety hazards while retaining the essential function of electrode production through dry powder formulation and processing.
2Object-affected harmful factors
If a dry process is used to manufacture electrodes, then toxic solvents are eliminated, but tight tolerances require consistent manufacturing process with uniform powder application
Solution Approach 1:
The patent implements feedback control through sensors that monitor powder characteristics (moisture content, particle size distribution, flow properties) in real-time. This feedback enables dynamic adjustment of powder delivery rates and calendering parameters to maintain uniform electrode thickness and meet tight tolerances despite variations in powder properties.
Solution Approach 2:
The patent employs dynamic control systems that continuously adjust powder delivery and calendering parameters based on real-time sensor data. This dynamic approach allows the system to adapt to varying powder characteristics and maintain consistent electrode quality, resolving the challenge of achieving uniform thickness in dry processing.
3Ease of manufacture
If solvents are used in electrode manufacturing, then the powder can be applied to substrate, but significant energy is expended for drying operations and solvent recovery
Solution Approach 1:
The patent extracts and eliminates the solvent component from the process, thereby removing the entire drying and solvent recovery energy consumption. Dry powder formulation and application require no thermal energy for evaporation or recovery, dramatically reducing energy usage while maintaining substrate coating capability.
4Ease of manufacture
If solvents are used in electrode manufacturing, then powder application is facilitated, but solvent recovery and disposal are required to prevent environmental harm
Solution Approach 1:
The patent removes the solvent substance from the manufacturing process entirely by using dry powder formulation. This elimination prevents all solvent-related environmental issues, including disposal requirements, while maintaining the ability to apply powder to substrate through dry calendering techniques.
Data Source
AI summary
Systems and methods of providing powder are disclosed. A system includes a powder hopper, one or more sensors, a feeder hopper and a processor in operable communication with the one or more sensors and the feeder hopper. The powder hopper is configured to provide a powder to a pair of rollers. Each of the one or more sensors is configured to determine a characteristic of the powder in the powder hopper. The feeder hopper is configured to provide the powder to the powder hopper. The processor is configured to cause the feeder hopper to provide the powder to the powder hopper in response to the characteristic of the powder in the powder hopper being less than a threshold.