Roll Coating Film Production Resin Layer Abrasion Prevention
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Solution Overview
Problem
Existing methods for producing electrochemical element electrodes result in surface abrasion of rolls due to friction with coating materials, leading to residual extraneous materials and increased defectiveness and reduced production efficiency.
Innovation Solution
A coating film production method and apparatus where a coating material is rolled between rolls to form a film, with residual material remaining on the roll surfaces, allowing the film to be transferred onto a coating object without direct contact, thereby suppressing abrasion and ensuring uniform film thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the coating material is supplied continuously and directly onto the surface of the first roll in the roll gap, then the coating material can be completely transferred from the first roll onto the second roll, but the surface of the first roll is easily abraded due to friction between the surface of the first roll and the mixture coating material
Solution Approach 1:
The patent introduces a resin layer as an intermediary substance between the first roll surface and the coating material. This resin layer mediates the contact, allowing the coating material to be transferred from the first roll to the second roll while preventing direct friction between the coating material and the roll surface, thereby suppressing abrasion of the first roll surface.
Solution Approach 2:
The patent changes the surface properties of the first roll by coating it with a resin layer, transforming the surface from a direct contact surface with coating material to a mediated surface. This parameter change in surface composition and friction characteristics resolves the contradiction between complete coating transfer and roll surface protection.
2Productivity
If the coating material is rolled between the rolls to form a coating film, then the coating film can be transferred onto the coating object, but residual extraneous materials are generated from the abraded roll surface, causing short-circuits and defectiveness
Solution Approach 1:
The resin layer acts as a mediator that prevents direct contact and friction between the coating material and the first roll surface. This eliminates the generation of extraneous materials from roll abrasion, thereby preventing short-circuits and defectiveness in the electrochemical elements while maintaining continuous coating film production.
Solution Approach 2:
The patent converts the potentially harmful direct friction between coating material and roll surface into a beneficial mediated contact through the resin layer. The resin layer absorbs the friction and wear, protecting the roll surface and ensuring high reliability of the produced electrochemical elements.
3Use of energy by stationary object
If the coating material is supplied directly onto the roll surface, then the coating process can proceed continuously, but the friction between the coating material and roll surface causes wear and deteriorates production efficiency
Solution Approach 1:
The resin layer serves as a continuous intermediary that enables uninterrupted coating operation while eliminating the harmful friction effects. This allows the coating process to proceed continuously without the roll surface wear that would otherwise deteriorate production efficiency.
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 effectively prevents roll abrasion and ensures uniform coating film transfer, enhancing the quality and efficiency of electrochemical element production by maintaining residual coating material layers on the rolls during the supply and transfer process.
Implementation Method 1
friction between the surface of the first roll 31 and the mixture coating material 33
Implementation Method 2
compressed to attach the coating material onto the surface of one of the rolls
Implementation Method 3
transferred the coating material in the form of a coating film, which is generated on the surface of the second roll, onto a coating object
Data Source
AI summary
When a coating material is rolled between rolls to generate a a coating film, and the coating film is transferred onto the coating object, at first, a residual coating material layer based on a residual coating material is formed on each of the surfaces of the rolls, and supply of the coating material and transfer of the coating film are carried out in a state where the residual coating material layer is retained on each of the surfaces of the rolls, thereby suppressing abrasions between the rolls and the coating material.