Separator Adhesive Coating Roll for Uniform Thick Point Patterns
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Solution Overview
Problem
Existing methods for forming incompletely covered coating adhesive layers on lithium-ion battery (LIB) separators struggle to accurately control the size, distance, and aggregation state of adhesive points, leading to irregular shapes and difficulties in producing uniform, thick coating films, which affects production quality and increases operational costs due to the need for replacing different intaglio rolls.
Innovation Solution
A dispensing device with a coating adhesive transferring device and a planar bottom roll, utilizing transferring protrusions on a relief roll to form uniform 'point-like' coating layers by adjusting feed amounts and spacings, and incorporating an abrasion detection system to maintain consistent thickness and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional PVDF spraying or slurry coating methods are used, then coating can be applied to separator, but the adhesive points cannot be accurately controlled in size, distance, and aggregation state, resulting in irregular shapes and poor production quality
Solution Approach 1:
The patent applies local quality by using discrete protrusions on the relief roll to create localized coating areas. Each protrusion transfers adhesive to a specific location on the separator, ensuring precise control over adhesive point size, distance, and aggregation state. This localized approach transforms the uniform coating problem into controlled point-wise application, directly resolving the manufacturing precision issue.
Solution Approach 2:
The relief roll acts as an intermediary between the adhesive supply and the separator. It receives adhesive from the anilox roll and selectively transfers it through its protrusions to the separator surface. This intermediary mechanism enables precise control over adhesive distribution, solving both the precision control and operational complexity problems by decoupling adhesive application from direct contact.
2Adaptability or versatility
If intaglio rolls are replaced to adjust coating thickness, then different thickness requirements can be met, but it causes high cost, troublesome operation, and waste of time
Solution Approach 1:
The patent applies dynamics by making the coating thickness adjustable through the spacing between the relief roll and the separator surface, rather than through fixed roll geometry. The feed amount controller dynamically adjusts the insertion depth of protrusions into accommodating grooves, and the spacing between rolls can be modified during operation. This dynamic adjustment mechanism eliminates the need for roll replacement, providing versatility while reducing time loss.
Solution Approach 2:
The patent changes physical parameters (spacing between rolls, insertion depth of protrusions) to adjust coating thickness instead of changing the physical structure of the rolls themselves. By controlling the feed amount through parameter adjustment rather than hardware replacement, the system achieves adaptability to different thickness requirements without incurring the costs and time losses associated with roll replacement.
3Quantity of substance
If the relief roll protrusions contact the separator directly, then thick coating films can be formed, but the shape becomes irregular and control on production quality deteriorates
Solution Approach 1:
The patent extracts the coating function from direct roll-to-separator contact by using protrusions that transfer adhesive droplets to the separator. The protrusions take out the adhesive from the rolling contact interface and deposit it in controlled locations on the separator surface. This extraction mechanism enables thick coating formation while maintaining shape consistency, as the adhesive is deposited in discrete, controlled portions rather than through direct pressure contact.
Solution Approach 2:
The rotating relief roll creates periodic action as its protrusions sequentially contact the separator surface at regular intervals. This periodic transfer of adhesive droplets ensures uniform distribution and consistent spacing between adhesive points. The periodic nature of the rotation provides rhythmic, controlled deposition that maintains manufacturing precision while building up coating thickness over multiple passes.
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
Enables the formation of stable and uniform coating layers with controlled thicknesses, reducing operational costs and time by allowing adjustment of coating thicknesses without replacing rolls, and improving the quality of LIB separators.
Implementation Method 1
the transferring protrusions are configured to insert into corresponding ones of the accommodating grooves on the adhesive accommodating device to transfer a separator coating adhesive
Implementation Method 2
a planar bottom roll 03 is used to squeeze the transferring surfaces of the protrusions 021 on the relief roll 02, such that the liquid film layers on the transferring surfaces of the protrusions 021 are transferred to separator 04
Implementation Method 3
the coating adhesive droplets on the transferring protrusions drip onto the coating film to form coating points on the coating film
Data Source
Figure 1
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AI summary
The present disclosure relates to the technical field of lithium-ion battery (LIB) separator preparation and in particular to a dispensing device for a LIB separator. The dispensing device for a LIB separator mainly includes a coating adhesive transferring device, a feed amount controller, and a planar bottom roll. The coating adhesive transferring device includes an adhesive accommodating device and a relief roll. Accommodating grooves for accommodating adhesives are provided on the adhesive accommodating device. Transferring protrusions are arranged on a rolling surface of the relief roll. The relief roll is located between the adhesive accommodating device and the planar bottom roll. The transferring protrusions are inserted into the accommodating grooves at a place where the relief roll contacts the adhesive accommodating device. The feed amount controller is configured to detect and control the feed amounts when the transferring protrusions are inserted into the accommodating grooves. The planar bottom roll is located under the relief roll. A film passing gap for allowing a coating film to pass through is provided between the planar bottom roll and the relief roll. The thicknesses of coating layers formed with the dispensing device are larger, and thicknesses and coverage rates of adhesive points are controlled simply and conveniently.