Separator Web Defect Positioning via Coordinate Recording
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Solution Overview
Problem
The production of separators for lithium-ion secondary batteries faces challenges in efficiently identifying and removing defects in separator original sheets, requiring significant efforts to specify the position of defects during the manufacturing process.
Innovation Solution
A method is developed to produce separator original sheets by forming, detecting, and recording defect information on the sheets, including positions in both width and longitudinal directions, allowing for easy identification and removal of defects during the production process. This involves forming a separator original sheet, detecting defects, recording defect information, and providing marks based on this information to specify the defect positions, which enables efficient defect removal during the slitting and winding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If defect detection and position specification methods are improved, then defect identification efficiency is improved, but measurement and detection difficulty worsens due to the large area of separator original sheets
Solution Approach 1:
The separator original sheet is divided into multiple inspection regions, and defects are detected and positioned within each region separately. This segmentation approach makes it easier to manage and specify defect positions on large-area sheets by breaking down the detection task into smaller, more manageable units.
Solution Approach 2:
A coordinate system is introduced as an intermediary to map defect positions on the separator original sheet. The coordinate system provides a standardized reference framework that simplifies the specification and communication of defect locations, transforming the complex task of position specification into a systematic coordinate-based approach.
2Loss of information
If defect information is recorded on the separator original sheet, then defect position specification is improved, but device complexity increases due to additional recording and marking systems
Solution Approach 1:
Defect information is extracted from the complex detection system and recorded in a simplified format on the separator original sheet itself. By taking out only the essential defect position information and marking it directly on the sheet, the system avoids the need for complex external recording and tracking devices, thereby reducing overall system complexity.
Solution Approach 2:
The separator original sheet serves its dual function as both the product being manufactured and the medium for recording defect information. The defect positions are marked directly on the sheet during the manufacturing process, allowing the sheet to 'record its own information' without requiring separate complex recording systems.
3Productivity
If the separator original sheet is stretched lengthwise during production, then production efficiency is improved, but defect position accuracy worsens due to displacement
Solution Approach 1:
Defect positions are recorded and marked on the separator original sheet before the sheet undergoes lengthwise stretching during production. By performing the defect marking action in advance, the system captures the defect positions in their original coordinates, which can then be accurately mapped to the final stretched product using the predetermined coordinate system, thereby maintaining position accuracy despite the stretching process.
Data Source
AI summary
To easily specify the position of a defect in a separator, a method for producing a separator original sheet (12b) includes the steps of: forming a separator original sheet (12b) including a separator original sheet (12c) and a heat-resistant layer coated on the separator original sheet (12c); detecting a defect (D) in the separator original sheet (12b); and recording information including information on a position of the defect (D) which position is a position in the width direction of the separator original sheet (12b).