Phenomena and Causes of Poor Coating Gap-Weinuojie Industrial

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Phenomena and Causes of Poor Coating Gap

Release date:

2021-07-14

1. **Web Breaks** (1) **Material Factors**: Slurry composition, viscosity, solids content, and slurry (surface) tension. (2) **Equipment Factors**: Coating-backup roller gap; coating roller speed when the backup roller expands; diameter of the backup roller; material used for the backup roller surface; potential deformation of the backup roller; alignment between the backup roller and coating roller; misalignment between the backup roller and the front roller in the oven; as well as operational tension levels. (3) **Operational Factors**: Parameters for adjusting the web at the start and end sections. 2. **Non-Parallel Start/End Sections** (1) **Material Factors**: Uneven tensile forces acting on both edges of the substrate. (2) **Equipment Factors**: Misalignment between the horizontal planes of the backup roller and coating roller; uneven expansion of the backup roller from side to side; lack of coaxial alignment on the backup roller’s surface; and misalignment between the backup roller and the traction roller—specifically, horizontal discrepancies.

Trailing tail

(1) Materials: Slurry material, viscosity, solids content, and slurry (surface) tension

(2) Equipment aspects: Coating-to-back-roll distance, coating roll speed during back-roll bounce, back-roll diameter, surface material of the back roll, back-roll deformation, parallelism between the back roll and the coating roll, misalignment between the back roll and the front roll of the oven, and tension during operation.

(3) Operational Aspects: Parameters for Head and Tail Adjustments

The ends are not parallel.

(1) Material aspect: Uneven attraction forces on both sides of the substrate.

(2) Equipment issues: The back roller and coating roller are not parallel to the horizontal plane; when the back roller springs open, it becomes uneven from side to side; there’s also misalignment in the coaxiality of the back roller surface, as well as a lack of parallelism between the back roller and the traction roller—resulting in changes to their horizontal alignment.

(3) Tension Adjustment Roller Adjustment Status

Front and back are misaligned

(1) Operational Issues: First, inconsistent gap alignment. Operating parameters are not properly adjusted. The light sensor is blocked. And the unwinding pinch roller has been left unclamped.

(2) Equipment: High tension on the back side of the second sheet, low tension on the front side.

When starting up, the blank space in the middle becomes smaller, and the last 3–4 pieces are inaccurate.

Equipment-wise: During initial startup, the tension was inaccurate, and the first side lacked memory functionality, causing the foil strip to slip forward by 2–3 mm upon power-up. Additionally, when starting up, the tension was activated before the back roller began rotating, and the coating head either didn’t have a pinch roll installed or wasn’t properly engaged.

The final segment features a parallel trailing tail.

Operation details: Adjust the nip roll gap (first side shows trailing, while the second side does not); when stopping the machine, the back rolls retract slowly.

Thick head, thin tail, or thin head, thick tail

Operation-wise: The start and end parameters are not properly adjusted.

There's action, but no effect.

(1) Material issue: The foil material has uneven tension on both sides.

(2) Equipment: The foil material leaves the backing roll momentarily due to low tension. Adjust the spacing of the coating-backing rolls.

The double-sided large-format blank space phenomenon

The photoreceptor shows no response, the first interfacial space is abnormal, and the photoreceptor is obscured.

Tags:

Causes of Wrinkling in Electrode Sheets During Coater Operation and Countermeasures

The Process Flow of the Coating Machine

Causes of Wrinkling in Electrode Sheets During Coater Operation and Countermeasures

The Process Flow of the Coating Machine

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