Separator Parallel Coating Layout for Continuous Multi-Pass Coating
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Solution Overview
Problem
Existing double-sided separator coating machines require multiple coating machines and additional production personnel and material transfer procedures, leading to reduced efficiency and increased costs when coating a separator multiple times.
Innovation Solution
A separator parallel coating device with a first and second coating apparatus arranged side by side, each including unwinding, coating, and oven mechanisms, and a reversing apparatus with reversing mechanisms to guide the separator between them, allowing for multiple coatings on each side without the need for additional machines or personnel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two independent coating machines are used to coat the separator four times, then the coating requirement is met, but the production efficiency is reduced and production cost is increased
Solution Approach 1:
The patent merges two independent coating machines into a single integrated coating device. The first and second coating apparatus are connected through a reversing mechanism, allowing the separator to be coated four times (twice on each side) within one continuous process. This integration eliminates the need for separate machines and reduces material transfer procedures, directly resolving the contradiction between meeting coating requirements and maintaining production efficiency.
Solution Approach 2:
The coating process maintains continuity through the reversing mechanism that enables the separator to pass from the first coating apparatus to the second coating apparatus without interruption. The separator undergoes four coating cycles in a continuous flow, eliminating idle time and transfer operations between independent machines, thus preserving productivity while achieving the required coating thickness.
2Manufacturing precision
If two independent coating machines are used to coat the separator four times, then the coating requirement is met, but the production cost is increased
Solution Approach 1:
The patent combines two separate coating machines into one integrated system with a shared reversing mechanism. This merger reduces the total number of machines from two to one, lowering equipment investment and operational costs while still achieving four coating cycles through the coordinated operation of the first and second coating apparatus.
Solution Approach 2:
The integrated coating device performs multiple functions: the first coating apparatus coats one side twice, the reversing mechanism flips the separator, and the second coating apparatus coats the other side twice. This multi-functional design eliminates the need for separate dedicated machines for each coating task, reducing device complexity and production cost.
3Device complexity
If a single coating machine is used, then the device complexity is reduced, but the coating times are insufficient
Solution Approach 1:
The patent introduces a dynamic reversing mechanism that enables the separator to change direction and be processed by different coating apparatus. This dynamic element allows a single integrated device to perform four coating cycles (twice on each side) without requiring four separate machines, maintaining low device complexity while achieving sufficient coating times.
Solution Approach 2:
The reversing mechanism adds a dimensional aspect to the coating process by enabling the separator to be flipped and processed from both sides. This transforms a single-sided coating capability into a multi-sided coating capability, allowing four coating cycles within one device without increasing complexity proportionally.
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 device reduces the number of production personnel and material transfer procedures, significantly improving production efficiency and lowering costs by enabling multiple coatings on a separator using a single setup.
Implementation Method 1
a reversing apparatus, which guides the separator from the first coating apparatus to the second coating apparatus
Data Source
AI summary
A separator parallel coating device includes a first coating apparatus, a second coating apparatus, and a reversing apparatus. The first coating apparatus and the second coating apparatus are arranged side by side in a front-rear manner, the first coating apparatus and the second coating apparatus each include an unwinding mechanism, an A-side coating mechanism, a first oven, a B-side coating mechanism, a second oven, a discharging traction mechanism, and a winding mechanism, the winding mechanism, the unwinding mechanism, the A-side coating mechanism, the first oven, and the B-side coating mechanism are sequentially arranged at intervals from left to right, the discharging traction mechanism is located above the unwinding mechanism and the A-side coating mechanism, the second oven is located above the first oven, and the reversing apparatus includes a first reversing mechanism, a second reversing mechanism, and a transition mechanism.