Segmented Transfer Rollers for Ultra-Wide Membrane Coating
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Solution Overview
Problem
Existing coating devices for secondary battery membranes are limited in width due to restrictions on the length and diameter of contact type coating rollers, leading to reduced productivity and increased manufacturing costs, with existing rollers warping or trembling under their own weight, resulting in defective products and low coating yields.
Innovation Solution
A coating device with a transfer roller that can be extended in length without warping, featuring two or more contact type coating rollers integrated by a connector with a thickness smaller than the diameter of the roller, allowing for large-width coating without limitations, using a housing with a roller groove and a coating solution supplier, and employing materials like poly tetrafluoro ethylene for the housing surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the length of the transfer roller is increased to achieve large-width coating, then the coating width is improved, but the roller warps or trembles due to its own weight causing defective products
Solution Approach 1:
The transfer roller is divided into multiple segments (first transfer roller, second transfer roller, third transfer roller) connected by connectors. Each segment has a manageable length that prevents warping and trembling, while the combined segments achieve the required large coating width. This segmentation resolves the contradiction by allowing wide coating without excessive roller length.
2Device complexity
If the diameter of the transfer roller is increased to reduce the number of rollers, then the device complexity is reduced, but the coating uniformity deteriorates due to warping and trembling
Solution Approach 1:
Instead of using a single large-diameter roller that would warp and tremble, the system uses multiple smaller-diameter rollers connected in series. Each smaller roller maintains structural stability and coating precision, while the combination achieves the required wide coating area, thus maintaining both simplicity and precision.
Solution Approach 2:
Multiple transfer rollers are merged into a single functional unit through connectors, allowing them to operate as one integrated coating system. This merging achieves the effect of a large-diameter roller without the negative effects of warping and trembling, maintaining coating uniformity while reducing the number of individual components needed.
3Device complexity
If a single long transfer roller is used to reduce device complexity, then the number of components is reduced, but the productivity decreases due to warping and trembling causing defective products
Solution Approach 1:
The transfer roller system is segmented into multiple manageable units connected by connectors. This segmentation prevents warping and trembling that would cause defective products, thereby maintaining high productivity while keeping the device complexity low through the integrated connector design.
Solution Approach 2:
The connectors allow for dynamic adjustment and flexible positioning of the segmented rollers, enabling the system to adapt to different coating requirements while maintaining structural stability. This dynamic flexibility ensures high productivity without compromising product quality.
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
The solution enables high productivity with a high coating yield and small loss rate of coating compositions, achieving excellent thermal stability and ionic conductivity for ultra large-width membranes, reducing manufacturing costs and improving coating uniformity.
Implementation Method 1
A surface of the housing may be made of at least any one selected from the group consisting of poly tetrafluoro ethylene and ultra high molecular weight polyethylene
Data Source
AI summary
Provided is an ultra large-width coating device applied to a consecutive process. More particularly, the present invention relates to a coating device capable of maximizing productivity by consecutively manufacturing a large-width film without reducing physical properties of the manufactured film by overcoming a problem in that a coating width is limited during a coating process using the existing contact type coating roller, and a method for manufacturing an ultra large-width membrane using the same.