Separator Coating Tank Partition for Ultrathin Uniform Layers
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Solution Overview
Problem
Conventional coating apparatuses for secondary battery separators fail to form uniform and ultrathin coating layers without affecting the operating conditions, leading to issues with thermal safety and resistance, which deteriorate battery performance.
Innovation Solution
A coating apparatus with a water tank partitioned into two zones, using polar and non-polar solutions, and guided by rollers to achieve an ultrathin coating thickness of 1 μm or less, with adjustable speed and heating for drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of a coating layer formed on a porous substrate is increased to improve thermal safety of the separator, then thermal safety is improved, but resistance is increased for the lithium secondary battery, causing battery performance to deteriorate
Solution Approach 1:
The invention changes the physical parameters of the coating process by controlling the coating solution layer height to be 0.5-2 mm and the moving speed to 0.1-10 m/min, which enables formation of ultrathin coating layers (1 μm or less) that provide adequate thermal safety while minimizing resistance
Solution Approach 2:
The invention introduces dynamic control of the coating process through adjustable moving speed of the substrate and controllable coating solution layer height, allowing optimization of coating thickness to balance thermal safety and resistance requirements
2Reliability
If a ceramic coating layer is formed on the separator to improve impregnability with electrolytic solution, then impregnability and mechanical characteristics are improved, but the coating layer acts as resistance, deteriorating battery characteristics
Solution Approach 1:
The invention changes the coating thickness parameter to ultrathin (1 μm or less) while maintaining ceramic material composition, which provides sufficient impregnability improvement without creating excessive resistance that would deteriorate battery characteristics
3Manufacturing precision
If conventional coating apparatuses are used to coat the separator, then coating can be performed, but it is difficult to form uniform and ultrathin coating layers without altering operating conditions
Solution Approach 1:
The invention converts static coating processes into dynamic ones by introducing controlled movement of the substrate through the coating solution at speeds of 0.1-10 m/min, enabling uniform ultrathin coating formation without complex process modifications
Solution Approach 2:
The invention optimizes the coating solution layer height parameter to 0.5-2 mm, which combined with controlled substrate movement, enables formation of uniform ultrathin coating layers using conventional coating apparatuses without altering their fundamental operating conditions
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 apparatus enables stable formation of ultrathin coating layers without altering conventional processes, improving battery characteristics by minimizing contaminants and maintaining mechanical properties.
Implementation Method 1
A coating apparatus with a water tank partitioned into two zones, using polar and non-polar solutions
Implementation Method 2
with adjustable speed and heating for drying
Implementation Method 3
The electrolytic solution permeates into spaces between the positive electrodes, the negative electrodes, and the separators by capillary force
Data Source
AI summary
A coating apparatus for continuously forming a coating layer on each surface of a substrate film includes a water tank located on a movement path of the substrate film, a water tank partition vertically located in the water tank, the water tank partition being configured to partition an inner space of the water tank into two zones, including a first water tank portion and a second water tank portion, a roller unit configured to continuously transfer the substrate film, and a heating unit located outside the water tank. The water tank partition is located spaced apart from an inner bottom surface of the water tank by a predetermined distance.