Radiation Basis Weight Gauging for Accurate Coating Measurement
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Solution Overview
Problem
Existing radiation basis weight gauges struggle to accurately measure the basis weight of coating materials due to varying correction factors between base and coating materials, especially when their atomic weights differ significantly, leading to inaccuracies in determining the actual basis weight of coating materials.
Innovation Solution
A system and method using x-ray and/or beta radiation basis weight gauges that determine the coating material corrected basis weight by calculating a coating material correction factor based on the differences between coated and base material uncorrected basis weights, employing upstream and downstream gauges and a controller to isolate and correct the coating material's basis weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a radiation basis weight gauge is used to measure the basis weight of a coating material, then the measurement can be performed continuously and non-destructively, but the measurement precision deteriorates when the atomic weights of the base material and coating material differ significantly
Solution Approach 1:
The measurement process is segmented into three distinct stages: (1) measuring the base material before coating application, (2) measuring the coated material after coating application, and (3) calculating the coating material basis weight by subtracting the base material weight from the coated material weight. This segmentation allows each measurement to be optimized independently, improving overall precision despite atomic weight differences.
Solution Approach 2:
The base material serves as an intermediary that enables indirect measurement of the coating material. By measuring the weight difference between the base material and the coated material, the system can determine the coating material's basis weight without directly measuring the coating alone, which would be difficult due to its thin nature. This intermediary approach maintains measurement continuity while improving accuracy.
2Ease of manufacture
If a single correction factor is used for both base material and coating material measurements, then the device operation is simplified, but the manufacturing precision deteriorates due to varying atomic weights
Solution Approach 1:
Different correction factors are applied locally to different measurement stages: one correction factor is used for measuring the base material, and a different correction factor is used for measuring the coated material. This local differentiation accounts for the varying atomic weights and composition differences between the base material and the coated material, ensuring high precision in each measurement stage while maintaining overall system simplicity through automated application of the appropriate correction factors.
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
This approach enables accurate determination of coating material basis weight, enhancing operational efficiency and reducing waste by minimizing errors in coating material application, particularly in battery cell components like anodes.
Implementation Method 1
utilizing x-ray and/or beta radiation basis weight gauges
Implementation Method 2
utilizing x-ray and/or beta radiation basis weight gauges
Implementation Method 3
determine a coated material uncorrected basis weight, based on a number of the measurement particles received at a radiation detector
Data Source
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AI summary
An example system, computer-implemented method, and computer program product for determining a basis weight of a coating material on a base material using radiation basis weight gauges is provided. An example system includes a radiation basis weight gauge and a controller. The radiation basis weight gauge is configured to direct measurement particles at a coated material, the coated material including a base material and a coating material, and determine a coated material uncorrected basis weight, based on a number of the measurement particles received at a radiation detector. The controller is configured to determine a base material uncorrected basis weight based on a base material corrected basis weight. The controller is further configured to use a coating material correction factor a determine the basis weight of the coating material based on a difference between the coated material uncorrected basis weight and the base material uncorrected basis weight.