Ribbon Electrode Coating With Real-Time Strip Alignment Correction
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Solution Overview
Problem
Existing methods for manufacturing ribbon-shaped electrodes with edge regions free of electrode material fail to achieve the required precision, especially in mass production, due to misalignment issues between coated strips on both sides of the current collector.
Innovation Solution
A method involving simultaneous double-sided coating of a ribbon-shaped metal foil with electrode material using multiple application nozzles, where each strip on one side overlaps with a corresponding strip on the other side, with real-time detection and correction of any offset to ensure precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sequential coating of both sides is performed, then manufacturing complexity is reduced, but manufacturing precision deteriorates due to misalignment between coated strips
Solution Approach 1:
The patent combines the coating operations for both sides of the current collector into a single simultaneous process using a multi-lane coating device with multiple nozzles. This merging of operations ensures that strips on both sides are applied at the same time, eliminating misalignment issues that would occur with sequential coating, while the integrated device design keeps the overall system complexity manageable.
Solution Approach 2:
The coating device incorporates adjustable and movable nozzles that can be dynamically positioned to accommodate variations in the current collector width and to optimize the coating pattern. This dynamic adjustability allows the system to maintain high precision across different production scenarios without requiring completely different coating configurations.
2Manufacturing precision
If multiple application nozzles are used for simultaneous double-sided coating, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The multi-lane coating device is designed as a universal system where multiple nozzles serve dual purposes: they can coat different sides of the current collector simultaneously and can be adjusted to accommodate various coating patterns and widths. This multi-functionality reduces the need for separate coating devices for each side, thereby managing complexity while achieving high precision.
Solution Approach 2:
The device uses identical or similar nozzle designs for coating both sides of the current collector, creating a replicated configuration that simplifies manufacturing and maintenance. By copying the successful single-side nozzle design to multiple lanes and both sides, the system achieves high precision without proportionally increasing complexity.
3Manufacturing precision
If offset detection and correction system is implemented, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent implements a feedback mechanism where the actual positions of the coated strips are monitored during the coating process, and any deviations from the desired alignment are detected. This feedback information is then used to make real-time adjustments to the nozzle positions or coating parameters, ensuring high precision without requiring overly complex pre-calibration systems.
Solution Approach 2:
The offset detection and correction system replaces complex mechanical alignment mechanisms with sensor-based detection and automated control systems. This substitution reduces mechanical complexity while achieving superior precision through electronic sensing and control, thereby managing the overall device complexity despite the added sophistication of the control system.
Data Source
AI summary
A method of manufacturing ribbon-shaped electrodes includes providing a ribbon-shaped metal foil and coating the ribbon-shaped metal foil with an electrode material in a continuous process to apply, via a plurality of application nozzles and simultaneously to a first side and to a second side, an equal number of parallel strips of the electrode material. Each respective parallel strip on the first side overlaps with a respective parallel strip on the second side. On both the first side and the second side, an uncoated strip-shaped region between adjacent parallel strips of the electrode material remains free of the electrode material. The method further includes detecting an offset that exceeds a predefined threshold value between overlapping strips on the first side and the second side and correcting, in response to detecting the offset, a position of at least one of the application nozzles relative to the ribbon-shaped metal foil.