X-ray and Beta Gauge Coating Weight Measurement
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Solution Overview
Problem
Conventional weight sensing for coated substrates, such as lithium-ion battery separator membranes, is complicated by the need for numerous calibration samples with uniform membrane and coating thickness, making quality control measurements challenging.
Innovation Solution
A measurement apparatus using an x-ray sensor and a second sensor, either a beta gauge or an infrared (IR) sensor, calculates the weight per unit area of the coating material and the sheet material independently, eliminating the need for conventional calibration through an x-ray based calculation that utilizes absorption coefficients and mathematical constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional weight sensing is used for coated substrates, then weight measurement is possible, but it requires numerous calibration samples with uniform membrane and coating thickness, making the process complicated
Solution Approach 1:
The patent replaces conventional mechanical weight sensing with a dual-method approach combining x-ray absorption measurement and beta gauge or infrared sensing. This substitution eliminates the need for complex calibration samples while maintaining measurement accuracy through physical property-based measurement (x-ray absorption coefficients and thermal/infrared properties)
Solution Approach 2:
The patent uses a composite measurement approach combining two different sensing methods (x-ray and beta gauge/IR) to measure different properties of the coated substrate. By measuring both the coating layer and substrate separately and combining the results, the system achieves accurate total weight measurement without requiring calibration samples
2Ease of manufacture
If x-ray based calculation is used to determine coating weight, then calibration samples are not needed, but additional sensors and calculation complexity are required
Solution Approach 1:
The patent segments the measurement process into two independent parts: x-ray measurement for coating layer weight and beta gauge/IR measurement for substrate weight. This segmentation allows each sensor to measure what it is optimized for, eliminating the need for calibration samples while keeping the overall system manageable through modular measurement
3Manufacturing precision
If dual sensor measurement is used, then both coating and substrate weight can be determined independently, but the device complexity increases
Solution Approach 1:
The patent introduces a computing system as an intermediary that receives signals from both sensors and performs the calculation to determine coating and substrate weights. This intermediary processes the raw sensor data using the relationship between total weight, coating weight, and substrate weight, simplifying the overall system architecture while maintaining high measurement precision
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
This method allows for accurate determination of the weight per unit area of both the coating material and the sheet material without requiring extensive calibration samples, enhancing quality control in the production of coated substrates.
Implementation Method 1
an x-ray sensor that provides a measured x-ray signal value, and a second sensor comprising a beta gauge or an infrared (IR) sensor that provides a second sensor signal which contains data for determining the total combined weight per unit area of the coated substrate
Implementation Method 2
a second sensor comprising a beta gauge or an infrared (IR) sensor that provides a second sensor signal which contains data for determining the total combined weight per unit area of the coated substrate
Implementation Method 3
a second sensor comprising a beta gauge or an infrared (IR) sensor that provides a second sensor signal which contains data for determining the total combined weight per unit area of the coated substrate
Data Source
AI summary
A measurement apparatus includes an x-ray sensor including an x-ray source having a high voltage power supply for emitting an x-ray spectrum and an x-ray detector for providing a measured x-ray signal value responsive to the x-rays received after transmission through a coated substrate including a sheet material having a coating material thereon. A second sensor is a beta gauge or infrared sensor for providing a second sensor signal that includes data for determining a total weight per unit area of the coated substrate or of the sheet material A computing device receives the measured x-ray signal value and the second sensor signal configured to implement an x-ray based calculation that utilizes absorption coefficients for the coating material and sheet material, the measured x-ray signal value, the x-ray spectrum, and the weight measure as a calculation constraint, for computing at least the weight per unit area of the coating material.