Patent Application
20230350385
The present invention refers to a computer-implemented method and a system for adjusting at least one drying process designated for producing at least one coating on at least one substrate as well as to a related method and system for continuously producing the at least one coating on the at least one substrate which involve the computer-implemented method and system. In particular, the present invention refers to adjusting at least one drying process which occurs during producing a battery electrode or a solar cell. However, further applications are feasible.
A drying process which is designated for producing at least one coating on at least one substrate as well as methods and systems for continuously producing the at least one coating on the at least one substrate are well-known. Adjusting such a drying process which may occur during a production process for a particular product, such as a battery electrode or a photoactive layer for a solar cell, may, especially, be driven to, concurrently, improve a product quality at constant or increasing process efficiency.
As an example, S. Jaiser, Film Formation of Lithium-Ion Battery Electrodes during Drying, Dissertation, Karlsruher Institut für Technologie (KIT), 2017, pp. 227-228, describes a basic approach to a reduction of a drying time of lithium ion battery anodes while using a particular drying profile. With regard to an adhesion of graphite anodes, an existence of a characteristic stage which exhibits a distinct sensitivity to drying boundary conditions has been demonstrated. A low evaporation rate was adjusted during the characteristic stage to prevent a binder from depleting at film domains close to the substrate. In order to reduce a total drying time, a high evaporation rate was adjusted during initial and final drying stages. For this purpose, the drying evaporation rate was solely altered by a variation in aerodynamic gas flow conditions. A film temperature during drying as well as a solvent loading in a gas phase were considered as major drying parameters.
As a further example, Sanyal et al., Adv. Energy Mater. 2011, 1, 363-367, describe the relevance of drying conditions for the manufacturing of organic solar cells. Further, Schmidt-Hansberg et al., ACS Nano 2011, 5, 11, 8579-8590 showed, that there also exists a certain critical instance in the drying step which is responsible for structure formation and consequently solar cell performance.
US 2019/081317 A1 discloses a dual sided coating system and a method for coating substrates, such as substrates useful as battery electrodes.
WO 2014/129214 A1 discloses a simulation device for drying a coating and a device for drying a coating.
Further, Ternes et al., Adv. Energy Mater. 2019, 9, 1901581 reveal a correlation between drying process parameters, a solar cell layer structure and a solar cell performance for perovskite solar cells.
It is, therefore, an object of the present invention to provide a computer-implemented method and system for adjusting at least one drying process designated for producing at least one coating on at least one substrate as well as to a method and a system for producing the at least one coating on the at least one substrate, which may at least partially overcome the above-mentioned technical disadvantages and shortcomings of known.
In particular, it is an object of the present invention to provide a simple and easily available access to adjusting at least one drying process designated for producing at least one coating on at least one substrate. It is, especially, desirable that the adjusting of the drying process may be designed to improve a quality of a product whose manufacturing includes at least one drying process at constant or increasing efficiency of the drying process, in particular with regard to at least one of a throughput during production, a performance of the at least one coating, and an energy consumption during the drying process.
This problem is solved by the invention with the features of the independent patent claims. Advantageous developments of the invention, which can be implemented individually or in combination, are presented in the dependent claims and/or in the following specification and detailed embodiments.
In a first aspect of the present invention, a computer-implemented method for adjusting at least one drying process designated for producing at least one coating on at least one substrate is disclosed. Herein, the at least one drying process is applied to at least one preparation deposited on the at least one substrate, wherein the at least one drying process comprises at least two consecutive drying stages after which the at least one coating is produced. According to the present invention, the method comprises the following steps:
In particular, the drying stage may be independent from the number or position of drying zones of the coating device.
The layout of the drying stage may in particular refer to the layout of a drying zone of the coating device.
As generally used, the term “computer-implemented method” relates to a particular kind of method which involves at least one programmable apparatus, in particular a computer, a server, a computer network, or a mobile communication device, wherein all steps of the method are implemented by using a computer program. The term “computer network” refers to any kind of infrastructure which comprises at least two computers and at least one communication interface, wherein at last one computer has access to at least one further computer via the at least one communication interface. Herein, the computer network can, preferably, be selected from at least one of an internet, an intranet or a local-area network. However, further kinds of computer networks may also be feasible. Further, the term “mobile communication device” refers to a particular type of programmable apparatus which is configured to be carried by a user and may, therefore, be moveable together with the user. Herein, the mobile communication device can, preferably, be selected from at least one of a smartphone, a tablet, or a personal digital assistant. However, further kinds of mobile communication devices may also be feasible.
As further generally used, the terms “computer program” and “software” relate to a series of computer-readable instructions configured to be provided to a programmable apparatus in order to perform at least one method step in consequence of at least one of the instructions. For this purpose, the computer program may comprise at least one algorithm configured to exert at least one particular operation by which the at least one method step is performed in a direct or an indirect fashion. The computer program can be selected from “software as a product”, which is configured to be transferred to at least one user, especially via payment and/or licensing, or from “software as a service”, which is configured to be centrally hosted and to be used by at least one user via at least one communication interface configured for network access, specifically on a subscription basis.
The computer-implemented method according to the present invention is designed for adjusting at least one drying process which is designated for producing at least one coating on at least one substrate, preferably in a coating device which is configured for this purpose. Herein, the at least one drying process is applied to at least one preparation which is deposited on the at least one substrate. As generally used, the term “preparation” refers to a substance which comprises at least two different components, i.e. at least one first component and at least one second component. Herein, the at least one first component may be or comprise a plurality of at least one solid component, wherein the at least one solid component may comprise a plurality of at least one of crystalline particles, amorphous particles, or dissolved molecules. Especially, an entirety of the solid components may also be denoted as “matrix”. Further, the at least one second component may be or comprise at least one fluidic component also be denominated by the term “solvent”, wherein the at least one solvent may be selected from at least one of a liquid, a gas, or a mixture thereof. In addition, the preparation may comprise at least one additional component, in particular at least one binder, wherein the term “binder” refers to a further substance designated to maintain the solid components within the matrix at least partially, preferably completely, together. However, further types of components may also be conceivable.
As generally used, the term “drying process” relates to an engineering procedure which is designated for reducing a content of the at least one second component, i.e. of the at least one solvent, which is comprised by the preparation to be dried, preferably until the content of the at least one solvent may be below a predefined threshold. In accordance with the present invention, the drying process is applied to at least one preparation to be dried which is deposited on at least one substrate. As a result of the drying process, the desired coating is produced on the at least one substrate. As further generally used, the term “substrate” refers to a mechanical support which is designated for receiving a portion of the preparation to be dried in the drying process and, subsequently, for maintaining the coating as the result of the drying process on the substrate. As further used herein, the term “depositing” refers to applying a portion of the preparation onto an adjacent surface of the substrate. The substrate may be selected from any material which is capable of receiving the portion of the preparation and of maintaining the coating as produced, wherein the substrate may, preferably, be inert, wherein the term “inert” relates to an observation that a contact of neither the preparation nor of the coating with the adjacent surface of the substrate may lead to any kind of degradation of the substrate.
As further indicated above, the at least one drying process comprises at least two consecutive drying stages after which the at least one coating is produced. As generally used, the term “drying stage” refers to a period of the drying process which is characterized by at least one value for at least one setting parameter for at least one associated dryer which is used during at least one of the drying stages. In particular, the at least one setting parameter for the at least one associated dryer may comprise at least one of an individual temperature profile and an individual heat transfer profile which may be applied during a corresponding drying stage. In other words, a particular drying stage is distinguished from an adjacent drying stage by selecting at least one value for the setting parameter for the at least one associated dryer in a fashion that it differs from the at least one value for the setting parameter for the at least one associated dryer in the adjacent drying stage. As used herein, the term “individual temperature profile” relates to a course of the temperature prevailing at the preparation during the corresponding drying stage while the term “individual heat transfer profile” refers to a course of the heat transfer applied to the preparation during the corresponding drying stage. Herein, the temperature may, specifically, refer to a temperature at an accessible surface of the at least one preparation as applied on the at least one substrate while the heat transfer may, especially, refer to a transfer of heat above the accessible surface of the at least one preparation. Herein, the at least one individual temperature profile may, preferably, be set by using at least one temperature control unit which is configured to control at least one of a heating unit or a cooling unit, while the at least one individual heat transfer profile may, preferably, be set by using at least one blowing unit. Herein, at last one of individual temperature profile or the individual heat transfer profile may, preferably, be set to a constant value during a particular drying stage.
The computer implemented method may further comprise the steps of providing the information about a layout of the at least two consecutive drying stages, about a composition of the preparation, and about the at least one substrate and receiving the at least one recommended procedure for adjusting the at least one drying process which comprises the at least one predictive value for the at least one setting parameter for the at least one associated suitable for being used during the at least one of the drying stages. Thus, the information may be remotely provided such as by or via an external server. Further, the at least one recommended procedure may be remotely received such as by or via an external server. With other words, both steps may be carried out at different or separate device.
In a particular embodiment of the present invention, the consecutive drying stages may comprise at least one initial drying stage and at least one critical drying stage which may follow the at least one initial drying stage. Herein, the at least one setting parameter for the at least one associated dryer may be adjusted during the at least one critical drying stage in a fashion to, generally, differ from the at least one setting parameter for the at least one associated dryer as adjusted during the at least one initial drying stage. In a further embodiment in which the drying process may comprise at least three consecutive drying stages, the at least three consecutive drying stages may further comprise at least one final drying stage which may follow the at least one critical drying stage. Herein, the at least one setting parameter for the at least one associated dryer during the at least one final drying stage may be adjusted in a fashion to, generally, to differ from the at least one setting parameter for the at least one associated dryer as adjusted during the at least one critical stage.
Not wishing to be bound by theory, the use of the different drying stages may be adapted to the composition of the at least one preparation. As already indicated above, the preparation, typically, comprises at least two different components, i.e. a matrix having a plurality of at least one solid component, wherein the at least one solid component may comprise a plurality of at least one of crystalline particles, amorphous particles or dissolved molecules, a solvent having at least one second component, wherein the at least one solvent may be selected from at least one of a liquid, a gas, or a mixture thereof, and, optionally, at least one binder designated to maintain the solid components within the matrix together. In order to form the coating during the at least one drying process, a combination of particle consolidation, binder migration and solvent evaporation occurs during the consecutive drying stages. In general, immediately after having applied the at least one preparation onto the at least one substrate, the at least one drying process, typically, commences with the initial drying stage which comprises a shrinkage of a volume of the at least one preparation on the at least one substrate, in particular, due to a combination of particle consolidation and solvent evaporation from the matrix. Thereafter, the critical stage, typically, commences when the shrinkage of the volume of the at least one preparation on the at least one substrate finishes and the solvent evaporation from pores between the consolidated particles commences. As experimentally demonstrated, it may, thus, be particularly preferred to apply a different drying profile during the critical drying stage to adequately support procedures which take place during the critical drying phase in order to obtain a high quality of the coating within as little time as possible. During the final drying stage, the value for the solvent volume fraction can, eventually, be reduced to almost zero, especially by applying a considerably high evaporation rate to reduce the drying time as far as possible.
In particular in a manufacturing of at least one of a positive electrode or a negative electrode for a battery, such as a lithium ion battery, the drying process may exhibit a specific mechanism. The coated preparation may, typically, comprise particles which can be dispersed in a binder solution, wherein the at least one binder can be selected from a dissolved polymer or a polymer dispersion. As a consequence of this particular preparation, a specific electrode formation mechanism during drying of the coating may occur. This mechanism exhibits at least two consecutive stages, in particular, three characteristic stages referring to the film composition space which is independent from the layout, in particular, number or position of drying zones of the coating and drying equipment. In an initial drying stage, the coated preparation on the substrate may be shrinking in the course of solvent evaporation, leading to a consolidation of the particles up to a formation of a porous network in which particles may have contact with each other, such that a shrinkage of the coating may be stagnating. In a subsequent drying stage, further solvent may be evaporating from the porous network. In the subsequent drying stage, the binder may be migrating to a surface with a rate which increases with the solvent evaporation rate as adjusted by dryer settings. In a final drying stage, the binder may not be sensitive to migration anymore, in particular due to a reduced solvent fraction and a, consequently, increased viscosity. For this specific mechanism, a particular drying process as used for drying at least one of a positive electrode or a negative electrode for a battery, such as a lithium ion battery, may, preferably, follow a specific three-stage drying process which differs from a typical drying process as used for other material systems, such for a drying of at least one photoactive layer in a coating of a solar cell, especially selected from an organic photovoltaic, a polymer solar cell or a perovskite-based solar cell, wherein the drying process may, however, also exhibit an impact on the final properties of the coating. In these mentioned photovoltaic related systems, the correlation between drying process and product performance underlies the mechanism of crystallization of salts, small molecules or polymers with decisive parameters such as crystal fraction, crystal size and orientation. This leads to different optimization criteria as well as fully different process parameters compared to battery electrodes. In battery electrodes the decisive mechanism is the formation of a binder and conductive additive gradient which governs the battery performance.
Providing the at least one recommended procedure for adjusting the at least on drying process based on drying stages that are independent from the number or position of drying zones of the coating and drying equipment allows adjusting according to the physical and chemical requirements. This may allow a more flexible adjustment of the production and therefore a better use of production capabilities, in particular while maintaining quality. The dependency from an existing physical coating device layout is reduced. Particularly, it is explicitly stated that a drying stage may be split, divided, partitioned or the like onto more than one drying zone such as two drying zone. With other words, one portion of a drying stage may be carried out or take place in a drying zone and another portion of the drying stage may be carried out or take place in another drying zone such as a consecutive drying zone.
In general, the drying process may be selected from a batch drying process or a continuous drying process, wherein the continuous drying process may, particularly, be preferred. As generally used, the term “the batch drying process” refers to a particular drying process in which each drying stage is performed consecutively on the same preparation, preferably, without moving the substrate, especially, within a single drying zone in which the at least two consecutive drying stages are, consecutively, performed. In contrast hereto, the term “continuous drying process” relates to a particular drying process which may, especially, be performed in a coating device which comprises at least one tape which is transported in a continuous fashion with a tape speed, preferably with a constant tape speed, through at least two consecutive drying zones, wherein each drying zone may, in particular, be designated for performing one of the at least two consecutive drying stages. Herein, the at least one tape may be or comprise the at least one substrate, or, as an alternative, the at least one tape may carry the at least one substrate for transport. Herein, at last one of individual temperature profile or the individual heat transfer profile may, preferably, be set to a constant value within a particular drying zone.
As further used herein, the term “adjusting” or any grammatical variation thereof relates to a procedure which is designated for arranging at least one parameter of the drying process in an desired fashion. Preferably, the adjusting of the drying process may be performed in a fashion that at least one material parameter of the at least one coating on the at least one substrate which is obtained by performing the at least one drying process may be improved at constant or, preferably, increasing efficiency of the drying process. As used herein, the term “efficiency” refers to at least one of a throughput during the production, a performance of the at least one coating, and an energy consumption during the drying process. In this manner, the product which involves the at least one coating on the at least one substrate may exhibit a higher quality which can be obtained at the same or, preferably, at lower efforts and expenses.
According to step (i), information about a layout of the at least two consecutive drying stages, about a composition of the preparation, and about the at least one substrate is received. Herein, the information about the layout of the at least two consecutive drying stages may, especially, comprise the layout of the drying zone, more particular, details about each drying zone and the at least one associated dryer which is used in each drying zone during a drying stage. Preferably, this piece of information may comprise at least one of a length of each drying zone; a type of dryer, preferably selected from at least one of a convective dryer, a radiative dryer, specifically based on infrared, UV, micro-wave, or radio-wave, or a contact dryer; at least one setting of the dryer, especially with respect to at least one location on a top or a bottom of the dryer, specifically at least one temperature; a blower setting; a ratio between fresh and recirculated drying gas which determines the fraction of evaporated solvent in the drying gas; a heat transfer coefficient; a convective drying nozzle slit width; a convective drying nozzle to nozzle distance; a convective drying nozzle distance to the substrate; a radiation source power; a distance in-between radiation sources; a distance radiation source to the substrate, a spectral distribution of the radiation source. Further, the information about the composition of the preparation may, preferably, comprise at least one of a type and concentration of the solid material, of the solvent, of a possible additive, a thickness and a coating weight per area of the preparation, or a porosity of the resulting coating. Further, the information about the at least one substrate may, preferably, comprise at least one of a type of the substrate, such as a foil, a non-woven, a woven, a fabric, a paper, or a glass substrate; a composition, a porosity, a thickness, or a weight per area of the substrate material. However, at least one further piece of information may also be feasible. Regarding step (i) it has to be noted that the information about a layout of the at least two consecutive drying stages, about a composition of the preparation, and about the at least one substrate may particularly be provided by a user of a drying apparatus comprising the two drying stages such as an operator of an industrial plant. The information about a layout of the at least two consecutive drying stages, about a composition of the preparation, and about the at least one substrate may then be received by a third party such as a supplier for the preparation. The information may be exchanged via any wired or wireless manner such as via the internet or any other network.
For receiving the pieces of information according to step (ii), the programmable apparatus on which the computer-implemented method as disclosed herein is performed comprises at least one of an input function or a communication interface by any one of which the desired pieces of information are provided in form of data to the programmable apparatus for further processing. As generally used, the term “input function” refers to a unit as comprised by the programmable apparatus which is configured to receive the pieces of information by manually or automatically generating the pieces of information for being used by the programmable apparatus. In particular, the input function may comprise at least one of a keypad, or a virtual keypad as displayed on at least one monitor. However further kinds of input functions may also be conceivable.
As further generally used, the term “communication interface” relates to a transmission channel designated for a transmission of data from a further programmable apparatus to the programmable apparatus on which the computer-implemented method as disclosed herein is performed. In particular, the communication interface may be arranged as a unidirectional interface which is configured to forward at least one piece of information into a single direction, especially to the programmable apparatus. Alternatively, the communication interface may be arranged as a bidirectional communication interface which is configured to forward at least one piece of data into one of two directions, or vice versa. Herein, the bidirectional communication interface can be used for forwarding requests or messages to the further programmable apparatus, such as a request for providing data or an error message. For the purpose of data transmission, the communication interface may comprise a wire-bound element or a wireless element. By way of example, the wire-bound element may be selected from at least one of a metal wire, such as a copper wire or a gold wire; a computer bus system, such as a universal serial bus (USB); or an optical fiber, whereas the wireless element may comprise a wireless transmitter or a Bluetooth element. However, further kinds of communication interfaces may also be feasible.
According to step (ii), at least one model is employed, wherein the at least one model is configured to generate at least one predictive value for at least one setting parameter for at least one associated dryer being used during at least one of the drying stages. As used herein, the term “model” relates to at least one computer program which is configured to generate a simulation of the drying process, wherein the drying process comprises the at least two consecutive drying stages. In particular, to achieve appropriate results, the simulation may closely be based on the information about the layout of the at least two consecutive drying stages, about the composition of the preparation, and about the at least one substrate as received during step (i). As further used herein, the term “employing” refers to a process of providing and using the at least one model, particularly in a fashion as required by the present invention. In order to employ the model, information on the preparation need to be provided such as information on the components thereof such as active material, binder, additives, solvent and composition in %. Thus, a specific coating weight in g/m2 may be defined as target setpoint, a tape speed in m/min, which relates to the throughput, and a ratio of circulating air in the drying zones may be determined.
The model may relate the information with drying stages for determining the at least one predictive value for the at least one setting parameter for the at least one associated dryer.
As further used herein, the term “predictive value” relates to at least one value which is determined by using the at least one model in a fashion that it can be used for the at least one setting parameter for the at least one associated dryer being used during the at least one of the drying stages. However, further predictive values may, additionally, be generated, in particular a predictive valued for a tape speed as described below in more detail.
In a particularly preferred embodiment, the at least one model may be generated by using at least one known value for the at least one setting parameter for the at least one associated dryer being used during the at least one of the drying stages. Herein, the at last one known value for the at least one setting parameter for the at least one associated dryer may, preferably, be acquired in at least one test drying process by using at least one known preparation on at least one known substrate which comprises at least one test layout of the at least two consecutive drying stages. The computer-implemented method according to any one of the preceding embodiments, wherein the at least one model is based on at least one of a composition of the preparation, at least one parameter related to at least one property of at least one component of the preparation, at least one measured value for at least one material parameter related to the at least one coating after the at least two drying stages, at least one known influence on crack formation in the at least one coating, and at least one value for an energy consumption as a consequence of the at least one setting parameter for the at least one associated dryer being used during at least one of the drying stages.
As a result of the test drying process, at least one relationship may be generated, wherein the at least one relationship may, preferably, refer to a plurality of values for the least one material parameter of the coating on the at least one substrate, specifically a peel strength indicating an adhesion of the at least one coating on the at least one side of the at least one substrate, and a plurality of setting parameters of an associated dryer in a corresponding drying zone. As exemplarily illustrated below, the at least one relationship may be displayed as at least one diagram, preferably a plurality of diagrams, in a two-, a three-, or a more-dimensional fashion. Herein, the at least one diagram may, especially, depict the relationship between the peel strength of the applied coating on the substrate and both the individual temperature profile and the individual heat transfer profile as applied during the corresponding drying stages to at least one particular preparation on at least one particular substrate. Herein, based on the at least one diagram which may, especially, depict the relationship between the peel strength of the applied coating on the substrate and both the individual temperature profile and the individual heat transfer profile as applied during the corresponding drying stages, the predictive value for both the individual temperature profile and the individual heat transfer profile within the particular drying stage may be determined in this fashion.
In a particularly preferred embodiment, the model may be generated by applying a combination of at least one data processing method, a set of selected features, and at least one learning algorithm. As generally used, the term “data processing method” refers to a process of modifying raw data, in particular a plurality of known values for the at least one setting parameter for the at least one associated dryer being used during the at least one of the drying stages, especially by using at least one of a correction algorithm, a smoothing algorithm, or a scaling algorithm. Further, the set of selected features may refer to at least one particular data item, preferably a plurality of values for the least one material parameter of the coating on the at least one substrate, specifically a peel strength indicating an adhesion of the at least one coating on the at least one side of the at least one substrate. As further generally used, the term “learning algorithm” relates to a process of extracting at least one pattern in at least one known set of data, wherein the at least one pattern can, thereafter, be applied to at least one unknown set of data. In addition, by using further unknown sets of data the at least one pattern can further be refined. Herein, the learning algorithm may, preferably, be selected from a machine-learning algorithm or a deep learning algorithm.
In particular, the determining of the at least one predictive value for the at least one setting for the at least one associated dryer being used during the at least one of the drying stages by using the information about the layout of the at least two consecutive drying stages, about the composition of the preparation, and about the at least one substrate may, preferably, be performed by applying the at least one learning algorithm to a combination of known predictive values with known pieces of information. Herein, the learning algorithm may involve at least one algorithm selected from at least one of a regression algorithm or a classification algorithm. By way of, example at least one of the following algorithms may be used: partial least square regression; discriminant analysis; a Bayesian algorithm such as Naïve Bayes, Brute-force MAP learning, Bayes Belief Networks, Bayes optimal classifier; Support Vector machines with multiple kernels; a decision tree algorithm such as random forest, CART; logistic and linear regression such as LASSO, Ridge, elastic net; a statistical analysis such as univariate generalized and mixed models; a neural network (NN) algorithm such as Fully connected NN, convolutional NN, recurrent NN; Gaussian modelling such as Gaussian process regression, Gaussian graphical networks; unsupervised learning methods such as non-negative matrix factorization, principal component analysis (PCA), t-sne, LLE. However, a further type of learning algorithm may also be feasible.
According to step (iii), the at least one predictive value for the at least one setting parameter for the at least one associated dryer being used during the at least one of the drying stages is determined based on the at least one model as employed during step (ii) and the information as received during step (i). For this purpose, the programmable apparatus as described elsewhere herein in more detail can, preferably, be used. Regarding step (iii) it has to be noted that this step is particularly not carried out by the user of the dryer apparatus but by a third party receiving the above-mentioned information such as a supplier of the preparation. This third party then starts the calculation procedure for determining the predictive value for the setting parameter(s). Thus, step (iii) relates to a prediction of a setting parameter which is subsequently useable for the drying process.
According to step (iv), at least one recommended procedure for adjusting the at least one drying process is provided. Herein, the at least one recommended procedure comprises the at least one predictive value for the at least one setting parameter for the at least one associated dryer being used during the at least one of the drying stages. As used herein, the term “recommended procedure” refers to a set of data comprising at least one proposal for adjusting the at least one drying process. Herein, the recommended procedure may, in particular, be provided to a user in order to initiate the user to implement at least one of, preferably all, of the proposals for adjusting the at least one drying process, for example by altering the tape speed and/or the at least one setting parameter for each associated dryer as used within the drying zones in the coating device, specifically in a manual fashion. As an alternative as described below in more detail, the recommended procedure can be provided to a control unit which is configured to control the coating device, especially by using at least one communication interface configured to exchange information between a programmable apparatus comprising a processing unit configured to generate the recommended procedure and the control unit. Regarding step (iv) it has to be noted that this step is particularly not carried out by the user of the dryer apparatus but by a third party receiving the above-mentioned information such as a supplier of the preparation. This third party then—having carried out the calculation procedure for determining the predictive value for the setting parameter—provides the user of the dryer apparatus with the recommended procedure. With other words, the third party provides a kind of manual or prescription and sends it to the user of the dryer apparatus which then may carry out the drying process according to the recommended procedure.
Briefly summarizing the first aspect of the present disclosure, the method may involve two different parties. The first party is the operator of a drying apparatus providing information about a layout of the at least two consecutive drying stages, about a composition of the preparation, and about the at least one substrate. The second party may be partly separate or remote from the first party. The second party predicts a recommended procedure for operating the drying apparatus based on the information provided by the first party and subsequently forwards the recommended procedure to the first party which then may correspondingly adjust the drying process.
In a further aspect, the present invention refers to a system for adjusting at least one drying process designated for producing at least one coating on at least one substrate. Herein, the system comprises:
In a preferred embodiment, the at least one further communication interface may be configured to provide the recommended procedure to a user, in particular via the screen. However, a further device for providing the recommended procedure to the user may also be feasible, such as a loudspeaker.
In a further preferred embodiment, the at least one further communication interface may be configured to provide the recommended procedure to a control unit configured to control the coating device.
In a further aspect, the present invention refers to a use of a computer-implemented method or of a system for adjusting at least one drying process designated for producing at least one coating on at least one substrate, in particular as described elsewhere herein, in an electrode for a vehicle application. Specifically, the use may refer to a positive electrode or a negative electrode for a battery, such as a lithium ion battery, which can be used in a vehicle application. More particular, the use may refer to a method for producing an electrode, specifically a positive electrode or a negative electrode for a battery, such as a lithium ion battery, as used in a vehicle application. However, further uses of the computer-implemented method or of the system for adjusting at least one drying process designated for producing at least one coating on at least one substrate may also be feasible, such as in producing at least one photoactive layer which can be used in a coating of a solar cell, such as in a photovoltaic solar panel.
In a further aspect, the present invention refers to a system for adjusting at least one drying process designated for producing at least one coating. Herein, the system comprises:
For further details with respect to the system for adjusting the at least one drying process designated for producing the at least one coating on the at least one substrate, the use of a computer-implemented method or of a system for adjusting at least one drying process designated for producing at least one coating on at least one substrate, and the system for adjusting at least one drying process designated for producing at least one coating, reference may be made to the description of the computer-implemented method for adjusting at least one drying process designated for producing at least one coating on at least one substrate and to the system for continuously producing the at least one coating on the at least one substrate as described elsewhere herein.
In a further aspect of the present invention, a method for continuously producing at least one coating on at least one substrate disclosed. The method comprises the following steps a) to f), which may, preferably, be performed in the given order, wherein at least two of the steps may be performed in an overlapping fashion in time. In addition, the method may comprise further steps which may be elsewhere be described herein or not. Accordingly, the method for continuously producing the at least one coating on the at least one substrate comprises the following steps:
For further details concerning the method for continuously producing at least one coating on at least one substrate, reference may be made to the description of computer-implemented method as presented herein according to one or more of the embodiments presented above or below in further detail.
In a further aspect of the present invention, a system for continuously producing at least one coating on at least one substrate is disclosed. Accordingly, the system comprises
As generally used, the term “drying zone” refers to a partition of the coating device which comprises at least one associated dryer that is operated by at least one value for at least one setting parameter as used within the drying zone. In particular, the at least one setting parameter for associated dryer may comprise at least one of an individual temperature and an individual heat transfer which may be applied within the corresponding drying zone. For this purpose, each drying zone may, preferably, comprise at least one of a heating unit or a cooling unit which can be controlled by at least one temperature control unit which configured to control the at least one individual temperature, and at least one blowing unit which designed to set the at least one individual heat transfer. By using multiple drying zones temperature and heat transfer profiles can be applied. Needless to say, a temperature and heat transfer profile can be realized in a single drying zone by varying the temperature and heat transfer, particularly over time.
As further used herein, the term “control unit” refers to an arbitrary kind of apparatus which is configured to control the coating device. In contrast to the term “adjusting” as defined above, the term “controlling” or grammatical variations thereof not only refers to for arranging at least one parameter of the drying process in an desired fashion but includes, in addition, reviewing whether the at least one parameter of the drying process has been adjusted in the desired fashion and, if required, further adjusting and reviewing the at least one parameter of the drying process. For a purpose of reviewing the at least one parameter of the drying process the coating unit may, in particular, comprise at least one sensor unit. Herein, the at least one sensor unit may, especially, be configured to record at least one measured value for at least one material parameter of the coating after the at least two consecutive drying zones. The sensor unit may, in particular, be configured to measure a temperature at at least one surface of the at least one coating, preferably by comprising at least one optical sensor, specifically at least one infrared sensor. Alternatively or in addition, the at least one sensor unit may be configured to measure a thickness or a coating weight per area of the at least one coating, preferably comprising using at least one of an ultrasonic sensor, an optical confocal sensor, an optical interference-based sensor, a laser triangulation sensor, a gamma-radiation based sensor, or a beta-radiation based sensor. Alternatively or in addition, the at least one sensor unit may be configured to measure a composition of the at least one coating, preferably by comprising a sensor based on infrared spectroscopy or on Raman spectroscopy. Alternatively or in addition, the at least one sensor unit may be configured to measure a structural information related to the at least one coating, preferably by comprising an eddy current sensor or a sensor based on optical microscopy, confocal microscopy, fluorescence microscopy, or interferometry. Alternatively or in addition, the at least one sensor unit may be configured to measure the gas phase composition such as the fraction of evaporating solvent preferably by using at least one of a flame ionization detector or other common gas sensors. However, further kinds of sensors may also be feasible.
In particular, the at least one control unit may comprise at least one further processing unit and a plurality of interface and, optionally at least one further device selected from at least one of a storage unit, a monitor, or a keyboard, Herein, the at least one further processing unit may, especially, be configured to drive the coating device, in particular by using the plurality of interfaces. Herein, at least one, preferably all, of the interfaces may be arranged as a bidirectional communication interface configured to transmit at least one piece of data into one of two directions, or vice versa. In particular, the interfaces can be used as bidirectional communication interfaces, preferably, in one direction, for transmitting instructions, especially for adjusting the at least one drying process by implementing the recommended procedure, from the at least one control unit to at least one of the at least one conveyor drive, the at least one application area, or the at least two consecutive drying zones, especially the temperature control unit and the blowing unit as comprised by each drying zone, and, in the other direction, for transmitting messages from at least one of the at least one conveyor drive, the at least one application area, or the at least two consecutive drying zones to the at least one control unit, such as data items, measurement values, or error messages. Further, the at least one control unit may be configured to interact with the at least one programmable apparatus, in particular, by using at least one, preferably bidirectional, communication interface. As an alternative, the at least one control unit and the at least one programmable apparatus may can be implemented within at least one combined programmable apparatus, especially in an embodiment in which the at least one combined programmable apparatus may be comprised by a stand-alone computer, a server, or a computer network.
For further details concerning the system for continuously producing at least one coating on at least one substrate, reference may be made to the description of computer-implemented method as presented herein according to one or more of the embodiments presented above or below in further detail.
In a further aspect of the present invention, a computer-implemented method for providing at least one recommended procedure for adjusting at least one drying process designated for producing at least one coating on at least one substrate is disclosed. Herein, the at least one drying process is applied to at least one preparation deposited on the at least one substrate, wherein the at least one drying process comprises at least two consecutive drying stages after which the at least one coating is produced. According to the present invention, the method comprises the following steps:
The methods and the systems according to the present invention provide various advantages with respect to methods and systems producing at least one coating on at least one substrate as known from prior art. In particular, it allows an individual setting of drying conditions in each drying zone in order to adjust the drying conditions during each drying stage. As a result of the possible adjusting of the drying process according to the present invention, a quality of a product whose manufacturing includes the at least one drying process can be improved at constant or increasing efficiency of the drying process. Hereby, at least one of a throughput during the production, a performance of the at least one coating, and an energy consumption during the drying process can be affected in a positive manner.
Particularly, the methods and the systems according to the present disclosure provide significant advantages if compared to design of experiments (DOE). Particularly, DOE is time, material, energy and resources consuming, particularly concerning production scale. A transfer of laboratory data to production scale usually requires a pilot apparatus which in turn is rather expensive. To the contrary, the method according to the present disclosure does not involve any experimental procedures but relates to a predictive procedure. Thus, a user of a drying or coating apparatus gains more time for manufacturing procedures rather than wasting time for optimizing the process. Thereby, the method according to the present disclosure is sustainable as it requires significant less raw materials and resources and does not require a pilot apparatus. Thus, the time necessary for the development from laboratory to production scale is significantly shortened and provides more time for the development of the coating process. Particularly, small adaptions or variations of the slurry manufacturing and/or coating process may be compensated and do not require complex and enduring experiments. Thus, the adjusted drying process increases the throughput which otherwise requires a new drying profile. Thus, more time for development of battery or solar cells is provided.
As used further herein, the terms “have”, “comprise” or “include” or any arbitrary grammatical variations thereof are used in a non-exclusive way. Thus, these terms may both refer to a situation in which, besides the feature introduced by these terms, no further features are present in the entity described in this context and to a situation in which one or more further features are present. As an example, the expressions “A has B”, “A comprises B” and “A includes B” may both refer to a situation in which, besides B, no other element is present in A (i.e. a situation in which A solely and exclusively consists of B) and to a situation in which, besides B, one or more further elements are present in entity A, such as element C, elements C and D or even further elements.
Further, as used herein, the terms “preferably”, “more preferably”, “particularly”, “more particularly”, “specifically”, “more specifically” or similar terms are used in conjunction with optional features, without restricting alternative possibilities. Thus, features introduced by these terms are optional features and are not intended to restrict the scope of the claims in any way. The invention may, as the skilled person will recognize, be performed by using alternative features. Similarly, features introduced by “in an embodiment of the invention” or similar expressions are intended to be optional features, without any restriction regarding alternative embodiments of the invention, without any restriction regarding the scope of the invention and without any restriction regarding the possibility of combining the features introduced in such a way with other optional or non-optional features of the invention.
Summarizing the above-mentioned findings, the following embodiments are preferred within the present invention:
Further optional details and features of the invention are evident from the description of preferred exemplary embodiments which follows in conjunction with the dependent Embodiments. In this context, the particular features may be implemented alone or in any reasonable combination. The invention is not restricted to the exemplary embodiments. The exemplary embodiments are shown schematically in the figures. Identical reference numerals in the individual figures refer to identical elements or elements with identical function, or elements which correspond to one another with regard to their functions.
In the Figures:
The system 110 according to the present invention comprises a coating device 120. Herein, the coating device 120 has a conveyor drive which is configured to move the tape 116 with a tape speed 122. As schematically depicted in
Further, the coating device 120 as schematically illustrated in
Further, the coating device 120 as schematically illustrated in
For this purpose, each drying zone 130, 130′, 130″ may comprise at least one temperature control unit (not depicted here) which is configured to set an individual temperature profile in the corresponding drying zone 130, 130′, 130″, specifically by controlling at least one of a heating unit or a cooling unit (not depicted here). As defined above, the individual temperature profile relates to a course of the temperature prevailing at the preparation within the corresponding drying zone 130, 130′, 130″, wherein the temperature may, specifically, refer to a temperature at an accessible surface of the at least one preparation as applied on the substrate 118, 118′.
In addition, each drying zone 130, 130′, 130″ may, further comprise at least one blowing unit (not depicted here) which is configured to adjust an individual heat transfer profile in the corresponding drying zone 130, 130′, 130″. As defined above, the individual heat transfer profile refers to a course of the heat transfer applied to the preparation within the corresponding drying zone 130, 130′, 130″, wherein the heat transfer may, especially, refer to a transfer of heat above the accessible surface of the at least one preparation.
In this manner, each drying zone 130, 130′, 130″ can, preferably, be addressed individually, preferably in a fashion that at least one value for the setting parameter for the associated dryer 132′ located in a particular drying zone 130′ differs from at least one value for the setting parameter for the associated dryers 132, 132″ located in adjacent drying zones 130, 130″. This advantage allows an individual setting of drying conditions in each drying zone 130, 130′, 130″ as described above and below in more detail.
As further schematically illustrated in
In general, the at least one material parameter of the coating 112, 112′ may depend on the nature and application of the coating 112, 112′. By way of example, the coating 112, 112′ on one or both sides 114, 114′ of the tape 116 can be a coating which is designated for being used in a battery electrode. Herein, the at least one material parameter can, preferably, be selected from a peel strength of the coating 112, 112′ on the substrate and an electrode performance of the coating 112, 112′ in an application of the battery electrode in an electrochemical cell. As a further example, the coating 112, 112′ on one or both sides 114, 114′ of the tape 116 can be designated for being used in a solar cell, wherein the at least one material parameter can be selected here from a peel strength of the coating 112, 112′ on the substrate and an electrical performance of the coating 112, 112′ in an application of the solar cell in a photovoltaic solar panel. However, further examples are feasible.
According to the present invention, the system 110 for producing the coating 112, 112′ on one or both sides 114, 114′ of the tape 116 further comprises a programmable apparatus 140. As schematically depicted in
As schematically illustrated in
In accordance with the present invention, the smartphone 144 is configured to receive information about a layout of the at least two consecutive drying stages 130, 130′, 130″, about a composition of the preparation, about the substrate 118, 118′, and about the tape speed 122. However, at least one further piece of information may, additionally, be received by the smartphone 144. As schematically illustrated in
In further accordance with the present invention, the smartphone 144 is further configured to employ at least one model which is configured to generate a predictive value 162 for the tape speed 122 and a predictive value 164 for the at least one setting parameter for each associated dryer 132, 132′, 132″ as used within the drying zones 130, 130′, 130″.
In further accordance with the present invention, the smartphone 144 is further configured to determine the predictive values 162, 164 for the tape speed 122 and for the at least one setting parameter for each associated dryer 132, 132′, 132″ as used within the drying zones 130, 130′, 130″, respectively, based on the at least one model as employed above and the information 154, 156, 158, 160 as further received above.
In further accordance with the present invention, the smartphone 144 is further configured to provide a recommended procedure 166 for adjusting the drying process. In the embodiment as schematically depicted in
In particular, the model may be generated by using known values for the composition of the preparation, the substrate 118, 118′, the layout of the consecutive drying stages 130, 130′, 130″, the tape speed 122, the at least one setting parameter for each associated dryer 132, 132′, 132″ and for at least one material parameter of the coating 112, 112′ on the substrate 118, 118′, specifically a peel strength indicating an adhesion of the coating 112, 112′ on the substrate 118, 118′. Herein, the known values may, preferably, be acquired in at least one test drying process by using at least one known preparation on at least one known substrate which comprises at least one test layout in a test coating device and one test tape speed. As a result of the test drying process, at least one relationship may be generated, wherein the at least one relationship may, for a particular preparation on a particular substrate to be dried in a particular layout as comprised by a particular coating device, refer to a plurality of values for the at least one material parameter of the coating 112, 112′ on the substrate 118, 118′, specifically the peel strength which indicates the adhesion of the coating 112, 112′ on the substrate 118, 118′, for a plurality of setting parameters of the associated dryer 132, 132′, 132″ within the corresponding drying zones 130, 130′, 130″ and the tape speed 122. As illustrated below in
In further accordance with the present invention, the recommended procedure 166 as provided by the smartphone 144 can initiate the user to alter the tape speed 122 and/or the at least one setting parameter for each associated dryer 132, 132′, 132″ as used within the drying zones 130, 130′, 130″ in the coating device 120, specifically in a manual fashion. However, as further shown in
As schematically depicted in
Therefore, in order to increase the quality of the coating 112, 112′, the drying profile 214 also denoted by the term “mild dying profile” can be used in which a low high evaporation rate (here r=1 g/m2s) may be applied to the preparation, and which provides the desired values for the at least one material parameter of the coating 112, 112′ after completion of the drying process, however, on cost of a particularly increased drying time 220. For both drying profiles 212, 214 a constant value for the setting parameters for the associated dryers 132, 132′, 132″ is being used during all drying zones 130, 130′, 130″ involved.
In accordance with the present invention, the recommended procedure 166 is provided, as described above, to adjust drying process by setting the tape speed 122 and/or the at least one setting parameter for each associated dryer 132, 132′, 132″ used within the drying zones 130, 130′, 130″ as comprised by the coating device 120. As illustrated in
As can be derived from
As a result, the drying process according to the partitioned drying profile 216 can be performed in an intermediate drying time 228 which, certainly, exceeds the drying time 218 as required for the rough drying profile 212 but which is still below the drying time 220 as required for the mild drying profile 214, by approximately 40% in this preferred exemplary embodiment, wherein a quality of the coating 112, 112′ as obtained by applying the partitioned drying profile 216 equals the quality of the coating 112, 112′ as obtained by applying the mild dying profile 214, which can be demonstrated by recording measured values for at least one material parameter of the coating 112, 112′ after completion of the drying process according to the partitioned drying profile 216.
Not wishing to be bound by theory, the results as presented in the diagram 210 of
In a receiving step 412 according to step (i), the information 154, 156, 158 about the layout of the at least two consecutive drying stages 222, 224, 226, about the composition of the preparation, and about the at least one substrate 118, 118′ is received.
In a employing step 414 according to step (ii), the at least one model is employed, wherein the at least one model is configured to generate the predictive values 162, 164 for the at least one setting parameter for each associated dryer 132, 132′, 132″ as being used during the drying stages 222, 224, 226.
In a determining step 416 according to step (iii), the predictive values 162, 164 for the at least one setting parameter for each associated dryer 132, 132′, 132″ as being during the three drying stages 222, 224, 226 is determined based on the at least one model as employed in the employing step 414 and the information 154, 156, 158 as received in the receiving step 412.
In a providing step 418 according to step (iv), the recommended procedure 166 for adjusting the drying process is provided, wherein the recommended procedure 166 comprises the predictive values 162, 164 for the at least one setting parameter for each associated dryer 132, 132′, 132″ during the three drying stages 222, 224, 226.
Further, the system 420 comprises the bidirectional communication interface 168 which is configured to function, on one hand, as a first communication interface configured to receive the information 154, 156, 158 about the layout of the at least two consecutive drying stages 222, 224, 226, about the composition of the preparation, and about the at least one substrate 118, 118′, and, on the other hand, as a further communication interface configured to provide the recommended procedure 166 for adjusting the drying process, which comprises the predictive values 162, 164 for the at least one setting parameter for each associated dryer 132, 132′, 132″ during the three drying stages 222, 224, 226, to the further processing unit 172 as comprised by the control unit 170 configured to control the coating device 120.
As further illustrated In
| Number | Date | Country | Kind |
|---|---|---|---|
| 20198988.6 | Sep 2020 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2021/076839 | 9/29/2021 | WO |
