Patent Description:
The present invention relates to a die coater and an inspection device thereof, and more specifically, to a die coater in which a position of a lip may be precisely measured to determine whether assembly defects of a die and a shim occur, and an inspection may be immediately performed when the die coater is in the state of being mounted on a production line without providing a separate inspection line, and an inspection device thereof.

In general, types of a secondary battery include a nickel cadmium battery, a nickel hydrogen battery, a lithium ion battery, a lithium ion polymer battery, and the like. Such a secondary battery is applied and used in small products such as digital cameras, P-DVDs, MP3P, mobile phones, PDAs, portable game devices, power tools, and e-bikes, as well as large products that require high power such as electric vehicles and hybrid vehicles, and power storage devices for storing surplus generated power or renewable energy, and power storage devices for backup power.

In order to manufacture the above secondary battery, electrode active material slurry is first applied on a positive electrode collector and a negative electrode collector to manufacture a positive electrode and a negative electrode, and the positive electrode and the negative electrode are stacked on both sides of a separator to form an electrode assembly having a predetermined shape. Then, the electrode assembly is accommodated in a battery case, followed by injecting an electrolyte thereto, and sealing.

An electrode such as a positive electrode and a negative electrode may be manufactured by applying slurry prepared by mixing an electrode active material, a binder, and a plasticizer with an electrode collector on an electrode collector such as a positive electrode collector and a negative electrode collector, and then drying and pressing the same. In order to apply such slurry on an electrode collector, a die coater is used.

A die coater generally includes a first die, a shim, and a second die, may be formed by assembling the first die and the second die with the shim interposed between the first die and the second die. At this time, a third die may be further provided between the first die and the second die, in which case a first shim may be interposed between the first die and the third die and a second shim may be interposed between the second die and the third die. That is, a die coater may include dies and shims in various numbers.

The die coater has a very narrow gap between discharge ports through which the slurry and the like are discharged. However, when such a gap differs from a designed gap due to an assembly tolerance or the like, the amount of slurry applied on an electrode collector and the like will greatly differ from a designed value. In that case, the quality of a manufactured electrode may be different from designed quality.

Alternatively, if a die coater is used for a long time once it is assembled, a die and a shim may be dissembled and then reassembled for internal cleaning or the like. However, in such a process, the positions of a first lip of the first die, a guide of the shim, a second lip of the second die may be deviated from their original positions. Then, even when the same die coater is used to manufacture an electrode, the quality of the electrode before and after the reassembly may be different.

Therefore, in order to reduce an assembly tolerance and the like, a user allows a lip of a die coater to be indirect contact with a micrometer so as to measure the height of a first lip, a shim, and a second lip and gaps therebetween. However, since the gap of a discharge port between such lips is very narrow, it is not easy for the user to make a direct contact therewith to perform measurement, and there is also a problem of increasing in errors due to different measurement results by each user. Document <CIT> discloses a double layer type die coater provided with manifolds for two coating material storages formed in the inside and made of a first metal material, a second metal material, and a third metal material and two slots which are spaces formed between the respective metal materials.

An object to be achieved by the present invention as defined in claim <NUM>, is to provide a die coater in which a position of a lip may be precisely measured to determine whether an assembly of a die and a shim is defective and an inspection may be immediately performed when the die coater is in the state of being mounted on a production line without providing a separate inspection line, and an inspection device thereof.

A device for inspecting a die coater including a first die, a second die, and a shim formed between the first die and the second die according to an embodiment of the present invention for solving the above problems includes a rail formed to be fixed long on one surface of the first die in a longitudinal direction of the die coater, and at least one sensor assembly configured to move along the rail and inspect a lip or the shim of the die coater, wherein the sensor assembly includes a movable part moving along the rail in the longitudinal direction of the die coater, and a sensor module connected to the movable part, and configured to move in a thickness direction of the die coater and inspect the lip or the shim.

In addition, the sensor module includes a position detection sensor configured to detect the position of the lip, and a distance detection sensor configured to measure the height of the lip or the shim.

In addition, the position detection sensor and the distance detection sensor may be disposed in parallel to each other in the longitudinal direction of the die coater.

In addition, the position detection sensor includes at least one of a fiber optic sensor, a photo sensor, a proximity sensor, or a vision sensor, and the distance detection sensor includes at least one of a laser displacement sensor or an ultrasonic displacement sensor.

In addition, the shim includes at least one guide configured to divide an internal space between the first die and the second die into a plurality of spaces, and a base connecting ends of the guide to each other and extending in a longitudinal direction of the die coater.

In addition, the position detection sensor moves along a first path in which the guide is not present, and the distance detection sensor moves along a second path in which the guide is present.

In addition, the sensor module may move in a direction from the first die to the second die.

In addition, a control part configured to control the operation of the sensor assembly, and a storage part in which reference data on the thickness of the lip or the shim is stored may be further included.

In addition, the control part may include a first encoder configured to recognize a coordinate value of the sensor module whenever the sensor module moves in the thickness direction of the die coater, a reception part configured to receive a signal transmitted by the position detection sensor, a determination part configured to determine the position of the lip or the shim according to the signal received by the reception part, and a calculation part configured to perform calculation based on the position of the lip or the shim and the coordinate value to derive a coordinate value of the lip or a coordinate value of the shim.

In addition, the position detection sensor may change a signal transmitted to the reception part from a first signal to a second signal, when detecting an edge of the lip.

In addition, the first encoder may recognize the coordinate value of the sensor module as a coordinate value of the edge, when the first signal is changed to the second signal.

In addition, the storage part may store the coordinate value of the edge recognized by the first encoder.

In addition, the determination part may determine the position of the lip or the shim using the edge as a boundary, when the reception part receives the second signal.

In addition, the calculation part may load the reference data on the thickness of the lip or the shim from the storage part and calculate reference data on the coordinate value of the edge and the thickness of the lip or the shim by reflecting the position of the lip or the shim to derive the coordinate value of the lip or the shim.

In addition, the calculation part may calculate half of the thickness of the lip or the shim to the coordinate value of the edge to derive the coordinate value of the lip or the shim.

In addition, the storage part may store the derived coordinate value of the lip or the shim.

In addition, the sensor module may move to a position corresponding to the derived coordinate value of the lip or the shim.

In addition, the distance detection sensor may measure the height of the lip or the shim at the position corresponding to the coordinate value of the lip or the shim.

In addition, the storage part may store measurement data on the height of the lip or the shim.

In addition, the storage part may have reference data on the height of the lip or the shim stored therein.

In addition, the determination part may compare the measurement data on the height of the lip or the shim with the reference data on the height of the lip or the shim to determine whether defects occur.

In addition, the control part may further include a second encoder configured to recognize a coordinate value of the movable part whenever the movable part moves along the rail in the longitudinal direction of may be coater.

In addition, the rail may be formed to be coupled to one surface of the first die.

In addition, the rail may be integrally formed on one surface of the first die.

In addition, the rail may be formed to be embedded on one surface of the first die.

In addition, the sensor assembly may be provided in plurality.

In addition, a height of the sensor module may be less than a gap between the lip and a base material to be coated.

In addition, the movable part may include a rod configured to move the sensor assembly in a width direction of the die coater.

In addition, the movable part may include a rotatable part configured to rotate around an axis parallel to the longitudinal direction of the die coater.

In addition, the movable part may be detachable from the rail.

In addition, the sensor module may include a 2D line sensor configured to scan the die coater so as to two-dimensionally detect the shape of the lip and the shim in the width direction of the die coater, and an inspection part configured to compare a measured height value from an edge of the lip to an edge of the shim detected through the 2D line sensor with a set height value to inspect whether defects occur.

In addition, the inspection part may inspect the arrangement state of two or more dies using the shape of the lip and the shim detected through the 2D line sensor.

In addition, the inspection part may inspect whether the edge of the lip detected by the 2D line sensor is positioned on the same horizontal line.

In addition, the inspection part may measure the thickness of the shim using the edge of the lip and the edge of the shim detected through the 2D line sensor, and inspect a discharge gap through the thickness of the shim.

In addition, the 2D line sensor may scan the die coater every set time to continuously detect the shape of the edge of the lip and the shape of the edge of the shim, and the inspection part may inspect a degree of wear of the die and the shim by a change in position with respect to the edge of the lip or a change in position with respect to the edge of the shim continuously measured through the 2D line sensor.

In addition, the inspection part may be configured to inspect surface roughness by enlarging the shapes of the lip and the shim detected through the 2D line sensor.

A die coater according to an embodiment of the present invention for solving the above problem includes a first die and a second die configured to supply slurry to the outside, and a shim formed between the first die and the second die, wherein a rail is formed to be fixed long on one surface of the first die in a longitudinal direction.

In addition, the die coater may further include at least one sensor assembly configured to move along the rail and inspect a lip or the shim, and a control part configured to control the operation of the sensor assembly, wherein the sensor assembly may include a movable part moving along the rail in a longitudinal direction, and a sensor module connected to the movable part, and configured to move in a thickness direction, and configured to inspect the lip.

In addition, the sensor module may include a position detection sensor configured to detect the position of the lip, and a distance detection sensor configured to measure the height of the lip or the shim.

Other specific details of the present invention are included in the detailed description and drawings.

According to the embodiments of the present invention, there are at least the following effects.

Since the die coater inspection device is formed on one surface of a first die of the die coater, there is no need for a user to perform measurement or separate setting, so that it is easy to measure the height, gap, and the like of a lip, and it is possible to reduce errors, thereby accurately determining whether an assembly of a die and a shim is defective.

In addition, it is possible to immediately inspect the die coater when the die coater is in the state of being mounted on a production line without moving the die coater to a separate inspection line, so that it is possible to reduce an inspection time and increase in production efficiency.

In addition, a die coater inspection device may automatically detect the position and height of the lip and the shim, the inspection may be easily performed, and the problem of increasing in errors due to the different measurement results by each user may be prevented.

The effects according to the present invention are not limited by the contents exemplified above, and more various effects are included herein.

Advantages and features of the present invention, and implementation methods thereof will be clarified through following embodiments described with reference to the accompanying drawings. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art. Further, the present invention is only defined by scopes of claims.

Unless otherwise defined, all the terms used herein (including technical and scientific terms) will be used in a sense that can be commonly understood to those of ordinary skill in the art to which the inventive concept pertains. In addition, the terms that are defined in a commonly used dictionary are not interpreted ideally or excessively unless specifically defined.

The terms used herein are for the purpose of describing embodiments and are not intended to be limiting of the present invention. In the present disclosure, singular forms include plural forms unless the context clearly indicates otherwise. As used herein, the terms "comprises" and/or "comprising" are intended to be inclusive of the stated elements, and do not exclude the possibility of the presence or the addition of one or more other elements.

<FIG> is a perspective view of a die coater <NUM> and a die coater inspection device <NUM> according to an embodiment of the present invention.

According to an embodiment of the present invention, the die coater inspection device <NUM> is formed on one surface of a first die <NUM> of the die coater <NUM>, so that there is no need to allow a user to directly perform measurement or separate setting, it is easy to measure a height, a gap, and the like of a lip <NUM> (illustrated in <FIG>), and it is possible to reduce errors, thereby accurately determining whether an assembly of a die <NUM> and a shim <NUM> (illustrated in <FIG>) is defective. In addition, it is possible to immediately inspect the die coater <NUM> when the die coater <NUM> is in the state of being mounted on a production line without moving the die coater <NUM> to a separate inspection line, so that it is possible to reduce an inspection time and increase in production efficiency. In addition, the die coater inspection device <NUM> may automatically detect the positions and heights of the lip <NUM> and the shim <NUM>, so that the inspection may be easily performed, and a problem of increasing in errors due to different measurement results by each user may be prevented.

To this end, in the device for inspecting the die coater <NUM> including the first die <NUM> (illustrated in <FIG>), the second die <NUM> (illustrated in <FIG>), and the shim <NUM> formed between the first die <NUM> and the second die <NUM>, the die coater inspection device <NUM> according to an embodiment of the present invention includes a rail <NUM> formed to be fixed long on one surface of the first die <NUM> in a longitudinal direction of the die coater <NUM>, and at least one sensor assembly <NUM> moving along the rail <NUM> and inspecting the lip <NUM> or the shim <NUM> of the die coater <NUM>. Here, the sensor assembly <NUM> includes a movable part <NUM> moving along the rail <NUM> in the longitudinal direction of the die coater <NUM>, and a sensor module <NUM> connected to the movable part <NUM>, moving in a thickness direction of the die coater <NUM>, and inspecting the lip <NUM> or the shim <NUM> of the die <NUM>.

In addition, the die coater <NUM> according to an embodiment of the present invention includes the first die <NUM> and the second die <NUM> which supply slurry to the outside, and the shim <NUM> formed between the first die <NUM> and the second die <NUM>. Here, the rail <NUM> is formed to be fixed long on one surface of the first die <NUM> in the longitudinal direction. In addition, at least one sensor assembly <NUM> moving along the rail <NUM> and inspecting the lip <NUM> or the shim <NUM>, and a control part <NUM> configured to control an operation of the sensor assembly <NUM> are further included. Here, the sensor assembly <NUM> may include the movable part <NUM> moving along the rail <NUM> in the longitudinal direction, and the sensor module <NUM> connected to the movable part <NUM>, moving in a thickness direction, and inspecting the lip <NUM>.

The rail <NUM> is formed long in the longitudinal direction of the die coater <NUM>. In addition, the movable part <NUM> of the sensor assembly <NUM> moves along the rail <NUM>. The rail <NUM> is formed to be fixed on one surface of the first die <NUM>, so that the die coater <NUM> and the rail <NUM> may not be easily separated or easily dislocated from each other. Therefore, there is no need to allow the user to directly measure the lip <NUM> of the die coater <NUM>, or separate setting a sensor, so that the sensor assembly <NUM> may easily inspect the lip <NUM> or the shim <NUM> formed at a side of a discharge port of the die coater <NUM>. In addition, since measurement results by each user are not different, the errors are reduced, and thus, it is possible to accurately determine whether the assembly of the die <NUM> and the shim <NUM> is defective. According to an embodiment of the present invention, the rail <NUM> may be formed to be coupled to one surface of the first die <NUM> through a separate coupling part (not shown) such as a bolt or a rivet, but is not limited thereto, and may be coupled to one surface of the first die <NUM> by various methods.

The sensor assembly <NUM> includes the movable part <NUM> moving along the rail <NUM> in the longitudinal direction of the die coater <NUM>, and the sensor module <NUM> connected to the movable part <NUM> and inspecting the lip <NUM> or the shim <NUM> of the die <NUM>.

The movable part <NUM> moves along the rail <NUM> in the longitudinal direction of the die coater <NUM>, and particularly, the movable part <NUM> may slide and move along the rail <NUM>. To this end, the rail <NUM> and the movable part <NUM> may be slidably coupled to each other, and furthermore, at least one of the rail <NUM> and the movable part <NUM> may have a wheel or a roller.

The sensor module <NUM> moves in the thickness direction of the die coater <NUM>, and may inspect the lip <NUM> or the shim <NUM>. As described above, when the height or the position of the lip <NUM> or the shim <NUM> differs from designed values due to an assembly tolerance or the like, the quality of a manufactured electrode may be different from designed quality. To this end, the sensor module <NUM> measures the height of the lip <NUM> or the shim <NUM>, and may confirm whether the die coater <NUM> is defective or not through the size of the assembly tolerance. The sensor module <NUM> is connected to the movable part <NUM>, and thus, also moves in the longitudinal direction of the die coater <NUM> when the movable part <NUM> moves along the rail <NUM>. Therefore the straightness of the lip <NUM> or the shim <NUM> of the die <NUM> may be inspected. In addition, when the sensor module <NUM> inspects the lip <NUM> or the shim <NUM> of the die <NUM>, the movable part <NUM> may move along the rail <NUM> and inspect the lip <NUM> or the shim <NUM> at various positions.

According to an embodiment of the present invention, the sensor module <NUM> includes a noncontact sensor, and inspects the height of the lip <NUM> or the shim <NUM>. Therefore there is no need to allow a user to directly contact the lip <NUM>, so that it is possible to prevent the problem in that errors occur. In addition, the sensor assembly <NUM> including the sensor module <NUM> moves along the rail <NUM>, and the rail <NUM> is formed to be fixed on one surface of the first die <NUM>, so that the sensor module <NUM> is not separated from the die coater <NUM>. Therefore, it is possible to immediately inspect the die coater <NUM> when the die coater <NUM> is in the state of being mounted on a production line without performing a process of moving the die coater <NUM> to a separate inspection line to perform measurement, and then moving the same back to the production line, so that it is possible to reduce an inspection time and increase in production efficiency. The sensor module <NUM> will be described in detail later.

<FIG> is an assembly view of the die coater <NUM> according to an embodiment of the present invention.

The die coater <NUM> is provided with slurry from the outside and then supplies the slurry to the outside, thereby applying the slurry on a base material such as an electrode collector long and continuously in a predetermined direction. To this end, the die coater <NUM> according to an embodiment of the present invention includes, as illustrated in <FIG>, the first die <NUM> and the second die <NUM> which supply the slurry to the outside, and the shim <NUM> formed between the first die <NUM> and the second die <NUM>, wherein the rail <NUM> is formed to be fixed long on one surface of the first die <NUM> in a longitudinal direction. Therefore the die coater <NUM> and the rail <NUM> may not be easily separated or easily dislocated from each other.

The die <NUM> applies slurry provided from the outside on at least one surface of a base material such as an electrode collector. At this time, as illustrated in <FIG>, two dies <NUM> are formed, and the die coater <NUM> may be formed by assembling the first die <NUM> and the second die <NUM> with one shim <NUM> interposed between the first die <NUM> and the second die <NUM>. However, the die coater <NUM> is not limited thereto, and may further include a third die <NUM> (illustrated in <FIG>) between the first die <NUM> and the second die <NUM>, in which case a first shim <NUM> (illustrated in <FIG>) may be interposed between the first die <NUM> and the third die <NUM> and a second shim <NUM> (illustrated in <FIG>) may be interposed between the second die <NUM> and the third die <NUM>. That is, the number of dies <NUM> and shims <NUM> included in the die coater <NUM> are not limited thereto, but may vary.

As illustrated in <FIG>, the first die <NUM> and the second die <NUM> have the shape of a truncated pyramid symmetrical to each other, and one surface of the first die <NUM> and the second die <NUM> corresponding to the bottom surface of the truncated pyramid are assembled to face each other. In addition, at least one of the first die <NUM> and the second die <NUM> may be provided with a supply hole (not shown) through which the slurry is supplied from the outside. The slurry supplied from the outside through the supply hole is stored in an internal space (not shown) formed inside the first die <NUM> and the second die <NUM>.

If the die coater <NUM> further includes the third die <NUM>, the third die <NUM> may have a thin rectangular plate shape. In addition, there are two shims <NUM> formed, and a first shim <NUM> is interposed between the first die <NUM> and the third die <NUM>, and a second shim <NUM> is interposed between the second die <NUM> and the third die <NUM>. In this case, both the first die <NUM> and the second die <NUM> may be formed in the supply hole (not shown), and a first internal space (not shown) may be formed inside the first die <NUM> and the third die <NUM>, and a second internal space (not shown) may be formed inside the second die <NUM> and the third die <NUM>. Therefore, the slurry supplied from the outside through each supply hole is stored in each of the first internal space and the second internal space.

The shim <NUM> for a die coater includes at least one guide <NUM> configured to divide an internal space between the first die <NUM> and the second die <NUM> into a plurality of spaces, and a base <NUM> connecting ends of the guide <NUM> to each other. The base <NUM> connects ends of at least one guide <NUM>, thereby supporting a plurality of guides <NUM>, and is formed extending from the ends of the at least one guides <NUM> in one side direction, particularly, in the longitudinal direction of the die coater <NUM>. Therefore, the base <NUM> may be formed in a simple rectangular shape, but is not limited thereto, and may have various shapes to adjust an amount of applied slurry.

The at least one guide <NUM> has a predetermined width, and is formed to be in parallel to each other. In addition, an internal space for storing slurry is formed inside the die <NUM>, and the guide <NUM> divides the internal space into a plurality of spaces. The slurry stored in the internal space flows inside the die coater <NUM> along the guide <NUM>, and is discharged to the outside through a discharge port. The discharge port is formed thin and long, the die coater <NUM> and the base material move relative to each other at a constant rate, so that the slurry may be widely and uniformly applied on the base material.

When the slurry is discharged through the discharge port and applied on the base material, a non-coating portion, a portion of the base material which is not applied with the slurry, may be formed by the guide <NUM>. Therefore the base material may be formed in a stripe pattern in which both the coating portion and the non-coating portion of the slurry are formed long in one direction while having a predetermined width. Since the coating portion and the non-coating portion are formed in such a stripe pattern, the non-coating portion becomes an electrode tab when a user cuts an electrode to an appropriate size later, so that it is easy to manufacture the electrode tab. In addition, by adjusting the width of the coating portion and the non-coating portion, the size of the electrode and the electrode tab may also be adjusted when cutting the electrode.

Hereinafter, the die coater <NUM> according to an embodiment of the present invention is described to have three dies <NUM> and two shims <NUM>. However, this is for convenience of description, and is not intended to limit the scope of rights.

<FIG> is a flowchart of a die coater inspection method according to an embodiment of the present invention.

In the method for inspecting the die coater <NUM> including the first die <NUM>, the second die <NUM>, and the shim <NUM> formed between the first die <NUM> and the second die <NUM>, a die coater inspection method according to an embodiment of the present invention using the above-described die coater inspection device <NUM> includes a process of moving the sensor module <NUM> including a position detection sensor <NUM>, a process of detecting an edge of the lip <NUM> of the die coater <NUM> by the position detection sensor <NUM>, a process of recognizing a coordinate value of the edge, a process of calculating the coordinate value of the edge and reference data on the thickness <NUM> to <NUM> (illustrated in <FIG>) of the lip <NUM> or the shim <NUM> to derive a coordinate value of the lip <NUM> or the shim <NUM>, a process of moving the sensor module <NUM> to a position corresponding to the coordinate value of the lip <NUM> or the shim <NUM>, a process of measuring the height of the lip <NUM> or the shim <NUM> by a distance detection sensor <NUM> included in the sensor module <NUM>, storing measurement data on the height of the lip <NUM> or the shim <NUM> in a storage part <NUM>, and a process of determining whether the die coater <NUM> is defective based on the measurement data on the height of the lip <NUM> or the shim <NUM>.

Hereinafter, each process illustrated in the flowchart of <FIG> will be described in detail with reference to <FIG>.

<FIG> is an enlarged side view of a lip <NUM> of the die coater <NUM> according to an embodiment of the present invention.

As described above, the sensor module <NUM> moves in the thickness direction of the die coater <NUM>, and may inspect the lip <NUM> or the shim <NUM>. According to an embodiment of the present invention, the sensor module <NUM> includes the position detection sensor <NUM> configured to detect the position of the lip <NUM>, and the distance detection sensor <NUM> configured to measure the height of the lip <NUM> or the shim <NUM>.

The position detection sensor <NUM> recognizes the position of the lip <NUM> when the sensor module <NUM> moves in the thickness direction of the die coater <NUM>, and in particular, may detect the position of the lip <NUM> by detecting an edge of the lip <NUM>. The position detection sensor <NUM> may include at least one of a fiber optic sensor, a photo sensor, a proximity sensor, or a vision sensor.

Particularly, the fiber optic sensor is manufactured using fiberglass, and is a sensor configured to detect a nearby object in a noncontact manner. In the optical fiber sensor, fiberglass itself may detect light, or if a separate element receives light, a fiberglass cable may transmit a signal for the received light. Unlike a typical photo sensor, the fiber optic sensor has a lens which may be removed, and thus, may be manufactured in an ultra-small size and may be easily installed in a narrow place. Examples of the fiber optic sensor include an optical time domain reflectometry (OTDR) sensor, an optical frequency domain reflectometry (OFDR) sensor, a brillouin optical time domain analysis (BOTDA) sensor, a brillouin optical correlation domain analysis (BOCDA) sensor, and the like.

As illustrated in <FIG>, in general, a base material (not shown), which is a coating target on which the die coater <NUM> applies slurry, may be seated on a plane, but may be seated on a roll <NUM> and pass as illustrated in <FIG>. At this time, if the thickness of the base material itself can be ignored, a gap g between the lip <NUM> of the die <NUM> and the base material is approximately <NUM>. Only when a height h of the sensor module <NUM> is less than the gap g between the lip <NUM> and the base material, the sensor module <NUM> may move in the thickness direction of the die coater <NUM> even when the die coater <NUM> is in the state of being mounted on a production line. Therefore, it is possible to immediately inspect the die coater <NUM> when the die coater <NUM> is in the state of being mounted on a production line without performing a process of moving the die coater <NUM> to a separate inspection line to perform measurement, and then moving the same back to the production line. Therefore, according to an embodiment of the present invention, the height h of the sensor module <NUM> may be less than the gap g between the lip <NUM> and the base material to be coated, and may be less than approximately <NUM>. In addition, it is preferable that the sensor module <NUM> moves between the lip <NUM> and the base material to be coated without being contacted or interfered by another component. Therefore, in order to control the above, the movable part <NUM> according to an embodiment of the present invention may include a rod for moving the sensor assembly <NUM> in a width direction of the die coater <NUM>.

The position detection sensor <NUM> according to an embodiment of the present invention may be manufactured in an ultra-small size, and detects the position of the lip <NUM> in a noncontact manner, and should detect the position of the lip <NUM> quickly and accurately even when the sensor module <NUM> is moving. To this end, it is preferable that the position detection sensor <NUM> according to an embodiment of the present invention is a fiber optic sensor. Particularly, since it is not possible to install a sensor separately inside the die <NUM>, a reflective sensor in which a light-transmitting part and a light-receiving part are not separately formed but all formed in one sensor body is preferable.

When a coordinate value of the lip <NUM> or the shim <NUM> is derived later, the distance detection sensor <NUM> measures the height of the lip <NUM> or the shim <NUM> at a position corresponding to the coordinate value of the lip <NUM> or the shim <NUM>. As the distance detection sensor <NUM>, a typical reflective displacement sensor may be used, and at least one of a laser displacement sensor and an ultrasonic displacement sensor may be included.

Particularly, when a laser transmitter transmits a laser, the laser displacement sensor measures a specific distance using the time taken until the laser is reflected by a corresponding object to return to be received. It is preferable that the distance detection sensor <NUM> according to an embodiment of the present invention is a laser displacement sensor.

<FIG> is a block diagram of the die coater inspection device <NUM> according to an embodiment of the present invention.

In the device for inspecting the die coater <NUM> including the first die <NUM>, the second die <NUM>, and the shim <NUM> formed between the first die <NUM> and the second die <NUM>, the die coater inspection device <NUM> according to an embodiment of the present invention includes the sensor module <NUM> moving in the thickness direction of the die coater <NUM> and inspecting the lip <NUM> or the shim <NUM> of the die coater <NUM>, the control part <NUM> configured to control the operation of the sensor module <NUM>, and a storage part <NUM> in which reference data on the thickness <NUM> to <NUM> (illustrated in <FIG>) of the lip <NUM> or the shim <NUM> is stored. Here, the sensor module <NUM> includes the position detection sensor <NUM> configured to detect the position of the lip <NUM>, and the distance detection sensor <NUM> configured to measure the height of the lip <NUM> or the shim <NUM>, and the control part <NUM> includes a first encoder <NUM> configured to recognize a coordinate value of the sensor module <NUM> whenever the sensor module <NUM> moves in the thickness direction of the die coater <NUM>, a reception part <NUM> configured to receive a signal transmitted by the position detection sensor <NUM>, a determination part <NUM> configured to determine the position of the lip <NUM> or the shim <NUM>, and a calculation part <NUM> configured to perform calculation based on the coordinate value to derive a coordinate value of the lip <NUM> or a coordinate value of the shim <NUM>.

Upon receiving a signal from the sensor assembly <NUM>, the control part <NUM> controls the operation of the sensor assembly <NUM> accordingly, that is, the operation of the sensor module <NUM> and the movable part <NUM>, calculates a coordinate value of the lip <NUM> or the shim <NUM>, and determines whether the die coater <NUM> is defective through the height of the lip <NUM> or the shim <NUM>. The control part <NUM> includes the first encoder <NUM>, the reception part <NUM>, the determination part <NUM> and the calculation part <NUM>. It is preferable that a central processing unit (CPU), a micro controller unit (MCU), a digital signal processor (DSP) or the like is used as the control part <NUM>, but various logical operation processors may be used without being limited thereto.

The storage part <NUM> stores programs for processing and controlling operations of the die coater inspection device <NUM> and various data or received signals generated during the execution of each program. The storage part <NUM> stores reference data on the thickness <NUM> to <NUM> of the lip <NUM> or the shim <NUM>, and also reference data on the height of the lip <NUM> or the shim <NUM>. In addition, in the storage part <NUM>, when the first encoder <NUM> recognizes a coordinate value of an edge, the coordinate value of the recognized edge is stored, and later when the calculation part <NUM> derives a coordinate value of the lip <NUM> or the shim <NUM>, the coordinate value of the lip <NUM> or the shim <NUM> is stored, and when the distance detection sensor <NUM> measures the height of the lip <NUM> or the shim <NUM>, measurement data on the height of the lip <NUM> or the shim <NUM> is also stored. The storage part <NUM> may be embedded in the die coater inspection device <NUM>, but may be provided as a separate storage server. The storage part <NUM> includes a non-volatile memory device and a volatile memory device. It is preferable that the non-volatile memory device is a NAND flash memory which is small in volume, lightweight, and resistant to external impacts, and the volatile memory device is a DDR SDRAM.

The first encoder <NUM> recognizes a coordinate value of the sensor module <NUM> whenever the sensor module <NUM> moves in the thickness direction of the die coater <NUM>. It is preferable that the first encoder <NUM> recognizes the coordinate value of the sensor module <NUM> in real time, and at this time, the coordinate value may be recognized by detecting an amount of movement of the sensor module <NUM> and converting the amount into coordinates. The coordinate value may be relative coordinates measured based on arbitrarily selected criteria. Then, later, when a first signal transmitted to the reception part <NUM> by the position detection sensor <NUM> is changed to a second signal, it means that the position detection sensor <NUM> has detected an edge of the lip <NUM>, so that the then coordinate value of the sensor module <NUM> may be recognized as a coordinate value of the edge.

The reception part <NUM> receives a signal transmitted by the position detection sensor <NUM>. The position detection sensor <NUM> changes a first signal to be transmitted to the reception part <NUM> to a second signal when an edge of the lip <NUM> is detected. Therefore whether the edge of the lip <NUM> has been detected or not may be notified to the control part <NUM>.

In accordance with a signal received by the reception part <NUM>, the determination part <NUM> determines the position of the lip <NUM> or the shim <NUM> using the edge as a boundary. That is, based on the edge, whether the lip <NUM> or the shim <NUM> is positioned in front of the sensor module <NUM>, and whether the lip <NUM> or the shim <NUM> is positioned at the rear of the sensor module <NUM> are determined. Here, the front refers to a direction in which the sensor module <NUM> moves, and the rear refers to a direction opposite to the direction in which the sensor module <NUM> moves. Then, later, when the distance detection sensor <NUM> measures the height of the lip <NUM> or the shim <NUM>, the measurement data on the height of the lip <NUM> or the shim <NUM> is compared with the reference data on the height of the lip <NUM> or the shim <NUM> to determine whether defects occur.

The calculation part <NUM> performs calculation based on the position of the lip <NUM> or the shim <NUM> and the coordinate value to derive a coordinate value of the lip <NUM> or a coordinate value of the shim <NUM>. Specifically, the reference data on the thickness <NUM> to <NUM> of the lip <NUM> or the shim <NUM> is loaded from the storage part <NUM>, and reference data on the coordinate value of the edge and the thickness <NUM> to <NUM> of the lip <NUM> or the shim <NUM> is calculated by reflecting the position of the lip <NUM> or the shim <NUM> to derive the coordinate value of the lip <NUM> or the shim <NUM>. Particularly, the calculation part <NUM> calculates half of the thickness <NUM> to <NUM> of the lip <NUM> or the shim <NUM> to the coordinate value of the edge to derive the coordinate value of the lip <NUM> or the shim <NUM>. At this time, the calculation varies depending on the position of the lip <NUM> or the shim <NUM>. If the lip <NUM> is positioned in front of the sensor module <NUM> and the shim <NUM> is positioned at the rear thereof based on the edge, the calculation part <NUM> adds half of the thickness <NUM> to <NUM> of the lip <NUM> to the coordinate value of the edge to derive the coordinate value of the lip <NUM>. Thereafter, the coordinate value of the shim <NUM> is derived by subtracting half of the thickness <NUM> and <NUM> of the shim <NUM> from the coordinate value of the edge.

The control part <NUM> may further include a second encoder <NUM>. The second encoder <NUM> recognizes a coordinate value of the movable part <NUM> whenever the movable part <NUM> moves along the rail <NUM> in the longitudinal direction of the die coater <NUM>. As described above, the sensor module <NUM> is connected to the movable part <NUM>, and thus, also moves in the longitudinal direction of the die coater <NUM> when the movable part <NUM> moves along the rail <NUM>. Therefore, the straightness of the lip <NUM> or the shim <NUM> of the die <NUM> may be inspected. At this time, the second encoder <NUM> may recognize a coordinate value of a portion at which straightness is poor by recognizing the coordinate value of the movable part <NUM>. Alternatively, data on a coordinate value of a portion in which the guide <NUM> of the shim <NUM> is present and a coordinate value of a portion at which the guide <NUM> of the shim <NUM> is not present may be loaded, and the sensor module <NUM> may automatically move to the corresponding coordinate, and inspect an assembly tolerance and the like of the lip <NUM> or the shim <NUM>. It is preferable that the second encoder <NUM> recognizes the coordinate value of the movable part <NUM> in real time, and at this time, the coordinate value may be recognized by detecting an amount of movement of the movable part <NUM> and converting the amount of movement into coordinates. The coordinate value may be relative coordinates measured based on arbitrary criteria.

Each element of the sensor assembly <NUM>, the control part <NUM> and the storage part <NUM> described so far may be implemented by software such as tasks, classes, subroutines, processes, objects, execution threads, and programs executed in a predetermined region on a memory, hardware such as a field-programmable gate array (FPGA) or an application-specific integrated circuit (ASIC), or by a combination of the software and the hardware. The elements may be included in a computer-readable storage medium, or a portion thereof may be divided and distributed in a plurality of computers.

In addition, each block may represent a module, segment, or portion of a code including one or more executable instructions for executing specified logical functions. In addition, in some alternative embodiments, it is also possible for the above-mentioned functions to occur out of order in the blocks. For example, two blocks illustrated in succession may in fact be performed substantially simultaneously, and the blocks may sometimes be executed in reverse order according to corresponding functions.

<FIG> is an enlarged top view of the lip <NUM> of the die coater <NUM> according to an embodiment of the present invention.

In order to perform a die coater inspection method using the above-described die coater inspection device <NUM>, the sensor module <NUM> is first moved in the thickness direction of the die coater <NUM>. As illustrated in <FIG>, the sensor module <NUM> may move in a direction from the first die <NUM> to the second die <NUM>.

The sensor module <NUM> includes the position detection sensor <NUM> and the distance detection sensor <NUM>, and the position detection sensor <NUM> and the distance detection sensor <NUM> may be disposed in parallel to each other in the longitudinal direction of the die coater <NUM>. In addition, as described above, the shim <NUM> for the die coater according to an embodiment of the present invention includes at least one guide <NUM>. In addition, the sensor module <NUM> moves so as to pass through the guide <NUM>, and at this time, in the sensor module <NUM>, the position detection sensor <NUM> may move along a first path R1 in which the guide <NUM> is not present, and the distance detection sensor <NUM> may move along a second path R2 in which the guide <NUM> is present. Therefore the position detection sensor <NUM> may recognize the edge of the lip <NUM> through the presence of the lip <NUM>, and the distance detection sensor <NUM> may measure the height of the lip <NUM> or the height of the shim <NUM>. Here, the height of the shim <NUM> is preferably the height of the guide <NUM> of the shim <NUM>.

While the sensor module <NUM> is moving in the thickness direction of the die coater <NUM>, the position detection sensor <NUM> detects the edge of the lip <NUM> S302. Then, the position detection sensor <NUM> changes a signal transmitted to the reception part <NUM> of the control part <NUM> from a first signal to a second signal.

A fiber optic sensor or a photo sensor may be a reflective sensor or a light-receiving type sensor. The reflective sensor is a sensor in which both a light-transmitting part and a light-receiving part are formed in one sensor body, so that when an object is detected, light is received in the light-receiving part. In addition, the light-receiving type sensor is a sensor in which a light-transmitting unit and a light-receiving unit are prepared and installed facing each other, so that when the light-receiving unit detects an object while receiving light, the light being received by the light-receiving unit is blocked. As described above, since it is not possible to install a sensor separately inside the die <NUM>, it is preferable that the position detection sensor <NUM> according to an embodiment of the present invention is a reflective sensor.

Meanwhile, the first encoder <NUM> recognizes a coordinate value of the sensor module <NUM> whenever the sensor module <NUM> moves. When the reception part <NUM> of the control part <NUM> receives the second signal from the position detection sensor <NUM>, the first encoder <NUM> recognizes a coordinate value of the sensor module <NUM> as a coordinate value of the edge S303. Thereafter, the storage part <NUM> stores the coordinate value of the edge.

For example, as illustrated in <FIG>, if the sensor module <NUM> moves while passing through an upper side of the first lip <NUM> of the first die <NUM>, the position detection sensor <NUM> detects the first lip <NUM>, so that an on signal, which indicates that a light-receiving part receives light, is transmitted to the reception part <NUM> of the control part <NUM>. However, when the sensor module <NUM> completely passes through the first lip <NUM>, a space in which the first shim <NUM> is interposed between the first die <NUM> and the third die <NUM> without the presence of the first lip <NUM> appears. However, as described above, the position detection sensor <NUM> moves along the first path R1 in which the guide <NUM> of the shim <NUM> is not present, so that the position detection sensor <NUM> detects nothing. That is, since a light-receiving part of the position detection sensor <NUM> does not receive light, an off signal is transmitted to the reception part <NUM>. Therefore, a point at which the sensor module <NUM> passes the moment when the light-receiving part of the position detection sensor <NUM> which has been receiving light no longer receives light is a first edge <NUM> of the first lip <NUM>. In addition, the moment when the signal transmitted by the position detection sensor <NUM> to the reception part <NUM> is changed from the on signal to the off signal, the first encoder <NUM> recognizes a coordinate value of the sensor module <NUM> as a coordinate value of the first edge <NUM>. Here, the first signal is the on signal, and the second signal is the off signal. In addition, the storage part <NUM> stores the coordinate value of the first edge <NUM>.

On the other hand, if the sensor module <NUM> moves while passing through an upper side of the space in which the first shim <NUM> is interposed, the position detection sensor <NUM> detects nothing, so that the off signal, which indicates that a light-receiving part does not receive light, is transmitted to the reception part <NUM> of the control part <NUM>. However, when the sensor module <NUM> completely passes through the space in which the first shim <NUM> is interposed, a third lip <NUM> of the third die <NUM> appears. Then, the position detection sensor <NUM> detects the third lip <NUM> and the light-receiving part receives light, the on signal is transmitted again to the reception part <NUM>. Therefore, a point at which the sensor module <NUM> passes the moment when the light-receiving part of the position detection sensor <NUM> which has not been receiving light receives light is a second edge <NUM> of the third lip <NUM>. In addition, the moment when the signal transmitted by the position detection sensor <NUM> to the reception part <NUM> is changed from the off signal to the on signal, the first encoder <NUM> recognizes a coordinate value of the sensor module <NUM> as a coordinate value of the second edge <NUM>. Here, the first signal is the off signal, and the second signal is the on signal. In addition, the storage part <NUM> stores the coordinate value of the second edge <NUM>.

As in the above manner, the position detection sensor <NUM> of the sensor module <NUM> may detect edges of the lip <NUM> of the die coater <NUM>, and the storage part <NUM> may store coordinate values of the edges.

Meanwhile, when the reception part <NUM> of the control part <NUM> receives the second signal from the position detection sensor <NUM>, the determination part <NUM> determines the position of the lip <NUM> or the shim <NUM> based on the detected edge. For example, when a signal received by the reception part <NUM> is changed from the on signal to the off signal, it indicates that the position detection sensor <NUM> has encountered a space in which the shim <NUM> is interposed while detecting the lip <NUM>. Therefore, based on the edge, the shim <NUM> is positioned in front of the sensor module <NUM>, and the lip <NUM> is positioned at the rear of the sensor module <NUM>. On the other hand, when a signal received by the reception part <NUM> is changed from the off signal to the on signal, it indicates that the position detection sensor <NUM> has detected the lip <NUM> after having passed through the space in which the shim <NUM> is interposed and detected nothing. Therefore, based on the edge, the lip <NUM> is positioned in front of the sensor module <NUM>, and the shim <NUM> is positioned at the rear of the sensor module <NUM>.

Furthermore, the determination part <NUM> determines whether the lip <NUM> whose position has been determined is which lip <NUM> between the first lip <NUM> to the third lip <NUM>, and determines whether the shim <NUM> is which shim <NUM> between the first shim <NUM> and the second shim <NUM>. As described above, the sensor module <NUM> moves in a direction from the first die <NUM> to the second die <NUM>, and the coordinate value of an edge of each lip <NUM> is stored. Therefore, if a signal received by the reception part <NUM> is first changed from the on signal to the off signal, it indicates that a corresponding edge is an edge of the first lip <NUM> and based on the edge of the lip <NUM>, the first shim <NUM> is position in the front and the first lip <NUM> is position at the rear.

Meanwhile, the storage part <NUM> also stores the reference data on the thickness <NUM> to <NUM> of the lip <NUM> or the shim <NUM>. Therefore, after the determination part <NUM> determines the position of the lip <NUM> or the shim <NUM> as described above, the calculation part <NUM> derives the coordinate value of the lip <NUM> or the shim <NUM> using the stored reference data on the thickness of the lip <NUM> or the shim <NUM>. From the beginning of manufacturing, there is designed data on the thickness <NUM> to <NUM> of the lip <NUM> or the shim <NUM> for the manufacturing. In addition, when the lip <NUM> or the shim <NUM> is a good product, it has a thickness within an error range of the designed data. Therefore, the reference data on the thickness of the lip <NUM> or the shim <NUM> may be the designed data.

The calculation part <NUM> loads the reference data on the thickness <NUM> to <NUM> of the lip <NUM> or the shim <NUM> from the storage part <NUM>. Thereafter, a coordinate value of the lip <NUM> or the shim <NUM> is derived by calculating half of the thickness of the lip <NUM> or the shim <NUM> to the coordinate value of the edge S304. At this time, the calculation is performed by reflecting the position of the lip <NUM> or the shim <NUM>.

For example, since the first shim <NUM> is positioned in the front and the first lip <NUM> is positioned at the rear based on the first edge <NUM>, the calculation part <NUM> loads the reference data on the thickness <NUM> of the first shim <NUM> and the thickness <NUM> of the first lip <NUM> from the storage part <NUM>. In addition, when half of the thickness <NUM> of the first shim <NUM> is added to the coordinate value of the first edge <NUM>, a coordinate value of the center point of the first shim <NUM> is derived, which is set as a coordinate value of the first shim <NUM>. In addition, when half of the thickness <NUM> of the first lip <NUM> is subtracted from the coordinate value of the first edge <NUM>, a coordinate value of the center point of the first lip <NUM> is derived, which is set as a coordinate value of the first lip <NUM>.

As in the above manner, the calculation part <NUM> may derive coordinate values of all the lips <NUM> and the shims <NUM> of the die coater <NUM>. In addition, the storage part <NUM> may store coordinate values of the lip <NUM> and the shim <NUM>.

Since the coordinate values of the lip <NUM> and the shim <NUM> are derived, the sensor module <NUM> moves to a position corresponding to the coordinate values S305. Thereafter, the distance detection sensor <NUM> included in the sensor module <NUM> measures the height of the lip <NUM> or the shim <NUM> at the position S306. The distance detection sensor <NUM> measures a distance at which each of the lips <NUM> or each of the shims <NUM> is spaced apart from the distance detection sensor <NUM>. Therefore, the height of the lip <NUM> or the shim <NUM> may be a relative height measured based on arbitrary criteria. However, the present invention is not limited thereto, and if the height of the distance detection sensor <NUM> from the ground surface is already stored in the storage part <NUM>, the height of the lip <NUM> or the shim <NUM> may be an absolute height measured from the ground surface. When the height of each of the lips <NUM> or the shims <NUM> is measured by the distance detection sensor <NUM> as described above, the measurement data is stored in the storage part <NUM>.

The determination part <NUM> may determine whether the die coater <NUM> is defective based on the measurement data of the lip <NUM> or the shim <NUM> S306. Specifically, the storage part <NUM> also stores reference data on the height of the lip <NUM> or the shim <NUM>. This may also be designed data for the manufacturing of the die coater <NUM>. Then, the determination part <NUM> loads the reference data on the height of the lip <NUM> or the shim <NUM> from the storage part <NUM>. Thereafter, the measurement data on the height of the lip <NUM> or the shim <NUM> may be compared with the reference data on the height of the lip <NUM> or the shim <NUM> to determine whether the die coater <NUM> is defective or not. If the measurement data is within an error range after the comparison of the two data, the assembly tolerance of the die coater <NUM> is not large, so that the determination part <NUM> determines that the corresponding die coater <NUM> is a good product. However, if the measurement data is out of the error range after the comparison of the two data, the assembly tolerance of the die coater <NUM> is large, so that the determination part <NUM> determines that the corresponding die coater <NUM> is defective.

<FIG> is a perspective view of a die coater 2a and a die coater inspection device 1a according to another embodiment of the present invention.

According to another embodiment of the present invention, as illustrated in <FIG>, a rail 11a is integrally formed on one surface of a first die <NUM>. Therefore the rail 11a and a die <NUM> may be more firmly fixed to each other than when formed coupled to each other through a separate coupling part. Therefore it is possible to more reliably prevent the die coater 2a and the rail 11a from being separated or dislocated from each other.

<FIG> is a perspective view of a die coater 2b and the die coater inspection device <NUM> according to further another embodiment of the present invention.

According to another embodiment of the present invention, as illustrated in <FIG>, a rail 11b is formed buried on one surface of a first die <NUM>. Thus, a volume of the die coater 2b in the thickness direction thereof may be reduced. At this time, the rail 11b and the first die <NUM> may be integrally formed, but the present invention is not limited thereto. The rail 11b and the first die <NUM> may be separately formed, or a recessed groove may be formed on one surface of the first die <NUM> and the rail 11b may be inserted into the groove and then coupled with a separate coupling part.

<FIG> is a perspective view of the die coater <NUM> and a die coater inspection device 1c according to further another embodiment of the present invention.

According to further another embodiment of the present invention, as illustrated in <FIG>, a plurality of sensor assemblies 12a, 12b, and 12c are provided. Therefore the plurality of sensor modules <NUM> may more quickly inspect a lip <NUM> or a shim <NUM> at various locations. <FIG> illustrates that three sensor assemblies 12a, 12b, and 12c are formed, but the present invention is not limited thereto. The sensor assemblies 12a, 12b, and 12c may be formed in various numbers.

<FIG> is a perspective view of the die coater <NUM> and a die coater inspection device 1d according to further another embodiment of the present invention.

According to further another embodiment of the present invention, as illustrated in <FIG>, the movable part <NUM> includes a rotatable part which rotates around an axis parallel to the longitudinal direction of a die coater <NUM>. When the die coater <NUM> is in the state of being mounted on a production line, a sensor assembly 12d immediately inspects the die coater <NUM>, and then the rotatable part rotates. Therefore the sensor assembly 12d is positioned outside of the die coater <NUM>, and there is no longer an obstacle present between the lip <NUM> of the die coater <NUM> and a base material to be coated. Then, the die coater <NUM> may immediately coat slurry on the base material, so that production efficiency may increase. In addition, when the die coater <NUM> is inspected again later, the rotatable part rotates in a reverse direction, so that a sensor assembly 12d may be positioned toward the lip <NUM> of the die coater <NUM>.

<FIG> is a perspective view of the die coater <NUM> and a die coater inspection device 1e according to further another embodiment of the present invention.

According to further another embodiment of the present invention, as illustrated in <FIG>, a sensor assembly 12e is detachable from a rail <NUM>. When a die coater <NUM> is in the state of being mounted on a production line, a sensor assembly 12e inspects the die coater <NUM>, and then the sensor assembly 12e is detached from the rail <NUM>. Therefore there is no longer an obstacle present between a lip <NUM> of the die coater <NUM> and a base material to be coated, and the die coater <NUM> may immediately coat slurry on the base material. In addition, when the die coater <NUM> is inspected again later, the sensor assembly 12e is mounted on the rail <NUM> again, so that the sensor assembly 12e may be positioned toward the lip <NUM> of the die coater <NUM>.

<FIG> are perspective views of the die coater <NUM> and a die coater inspection device 1f according to further another embodiment of the present invention.

According to another embodiment of the present invention, as illustrated in <FIG>, at least one sensor assembly 12f moving along the rail <NUM> and inspecting the lip <NUM> or the shim <NUM> of the die coater <NUM> is provided.

The sensor assembly 12f includes a movable part <NUM> moving along the rail <NUM> in the longitudinal direction of the die coater <NUM>, and a sensor module <NUM> connected to the movable part <NUM> and inspecting the lip or the shim while moving in the thickness direction of the die coater <NUM>.

The sensor module <NUM> includes a 2D line sensor <NUM> connected to the movable part <NUM> and scanning a discharge port portion of the die coater <NUM> to two-dimensionally detect the shape of the lip <NUM> and the shape of the shim <NUM> in the width direction of the die coater <NUM>, and an inspection part <NUM> comparing a measured height value obtained by measuring the height from an edge of the lip <NUM> to an edge of the shim <NUM> detected through the 2D line sensor <NUM> with a set height value which has already set to inspect whether defects occur.

The 2D line sensor <NUM> scans the die coater <NUM> in the width direction of the die coater to detect a shape in which the lip <NUM> and the shim <NUM>, which are included in the die coater <NUM>, are connected, in a two-dimensional image. That is, the 2D line sensor <NUM> detects a side surface image of the die coater <NUM> as illustrated in <FIG>. In more detail, referring to <FIG> and <FIG>, the 2D line sensor <NUM> detects an image in which the first lip <NUM> of the first die <NUM> on the right side, the second lip <NUM> of the second die <NUM> on the left side, the third lip <NUM> of the third die <NUM> between the first and second dies <NUM> and <NUM>, the first shim <NUM> between the first die <NUM> and the third die <NUM>, and the second shim <NUM> between the third die <NUM> and the second die <NUM> are connected in a concave-convex shape.

At this time, the 2D line sensor <NUM> is also referred to as a 2D laser displacement sensor or line scanner, and has a wide laser light source is wide, and thus, may measure a shape representing such as the width, area, thickness, height difference, inclination, curve, surface roughness, and degree of wear of a lip or a shim in two dimensions.

Particularly, the 2D line sensor <NUM> moves in the longitudinal direction of the die coater <NUM> by the movable part <NUM>, and accordingly, may detect a shape in which a lip and a shim are connected over the entire die coater <NUM> in an image.

Meanwhile, a height h of the 2D line sensor should be less than the gap g between the lip <NUM> and a base material to be coated. This allows the 2D line sensor <NUM> to move in the width direction of the die coater <NUM> even when the die coater <NUM> is mounted on a production line. Therefore it is possible to immediately inspect the die coater <NUM> when the die coater <NUM> is in the state of being mounted on a production line without performing a process of moving the die coater <NUM> to a separate inspection line to perform measurement, and then moving the same back to the production line. Accordingly, the height h of the 2D line sensor <NUM> is less than the gap g between the lip <NUM> and a base material to be coated. For example, when the gap g between the lip <NUM> of the die <NUM> and the base material is approximately <NUM>, the height h of the 2D line sensor <NUM> may be less than approximately <NUM>. In addition, it is preferable that the 2D line sensor <NUM> moves between the lip <NUM> and the base material to be coated without being contacted or interfered by another component. Therefore, in order to control the above, the movable part <NUM> according to an embodiment of the present invention may include a rod for moving the sensor assembly 12f in the width direction of the die coater <NUM>.

The inspection part <NUM> measures the height between a lip and a shim through an image of the lip and the shim detected through the 2D line sensor <NUM>, and compares a measured height value measured with a set height value already set to inspect whether there is an assembly defect or not. That is, when the measured height value is within the range of the set height value, the inspection part <NUM> determines that there is no defect, and when out of the range, determines that there is an assembly defect.

In more detail, the inspection part <NUM> primarily inspects whether there is an assembly defect by comparing a first measured height value obtained by measuring the height between a lip and a first shim with a set height value, and then secondarily inspects whether there is an assembly defect by comparing a second measured height value obtained by measuring the height between the lip and a second shim with the set height value. Accordingly, when both the primary inspection and the secondary inspection show that there is no defect, an assembly is determined to be normal, and when either the primary inspection or the secondary inspection shows that there is a defect, the assembly is determined to be defective.

Meanwhile, the inspection part <NUM> inspects the arrangement state of two or more dies using the two-dimensional image of the shape in which the lip <NUM> and the shim <NUM> are connected detected though the 2D line sensor <NUM>. That is, the inspection part <NUM> inspects whether the first lip <NUM>, the second lip <NUM>, and the third lip <NUM> are positioned on the same horizontal line, and at this time, when any of the lips is not positioned on the same horizontal line, determines that there is an assembly defect.

Meanwhile, the inspection part <NUM> inspects whether lips (that is, the first and second lips) provided in two or more dies <NUM> are positioned on the same horizontal line by using a two-dimensional image shape with respect to the edge of the lip <NUM> detected through the 2D line sensor <NUM>. That is, when the first lip and the second lip are not positioned on the same horizontal line, the inspection part <NUM> determines that there is an assembly defect.

Meanwhile, the inspection part <NUM> measures the thickness of the shim <NUM> using a two-dimensional image shape with respect to the edge of the lip <NUM> and the edge of the shim <NUM> detected through the 2D line sensor <NUM>, and inspects a discharge gap through the thickness of the shim <NUM>. That is, when a measured discharge gap and a set discharge gap do not match, the inspection part <NUM> determines that there is an assembly defect.

Meanwhile, the inspection part <NUM> may inspect surface roughness by enlarging a two-dimensional image shape of the lip <NUM> and the shim <NUM> detected through the 2D line sensor <NUM>. At this time, the inspection part <NUM> may determine that there is a defect when the surface roughness of the lip and the shim exceeds a set value.

Meanwhile, in the sensor assembly 12f, the 2D line sensor <NUM> scans the die coater <NUM> every set time to continuously detect the shape of the edge of the lip <NUM> and the shape of the edge of the shim <NUM>, and the inspection part <NUM> inspects the degree of wear of the die <NUM> and the shim <NUM> by a change in position with respect to the edge of the lip <NUM> or a change in position with respect to the edge of the shim <NUM> continuously measured through the 2D line sensor <NUM>. Here, the inspection part <NUM> may inspect the surface roughness of the die and the shim through surface roughness with an image of the lip and the shim measured through the 2D line sensor <NUM>.

Meanwhile, the sensor assembly 12f may further include a moving rod <NUM> which moves the 2D line sensor <NUM> in the width direction of the die coater <NUM> such that the 2D line sensor <NUM> may scan from one end to the other end in the width direction of the die coater <NUM>. Accordingly, the 2D line sensor <NUM> may stably and entirely scan in the width direction of the die coater <NUM>.

Meanwhile, it is preferable that a central processing unit (CPU), a micro controller unit (MCU), a digital signal processor (DSP) or the like is used as the control part <NUM>, but various logical operation processors may be used without being limited thereto.

Claim 1:
A die coater inspection device (<NUM>) for inspecting a die coater (<NUM>) comprising a first die (<NUM>), a second die (<NUM>), and a shim (<NUM>) formed between the first die (<NUM>) and the second die (<NUM>), the die coater inspection device (<NUM>) comprising:
a rail (<NUM>); and
at least one sensor assembly (<NUM>) configured to move along the rail (<NUM>) and inspect a lip (<NUM>) or the shim (<NUM>) of the die coater (<NUM>),
wherein the sensor assembly (<NUM>) comprises:
a movable part (<NUM>) moving along the rail (<NUM>) in the longitudinal direction of the die coater (<NUM>); and
a sensor module (<NUM>) connected to the movable part (<NUM>), configured to move in a thickness direction (R1, R2) of the die coater (<NUM>) and inspect the lip (<NUM>) or the shim (<NUM>), and comprising a distance detection sensor (<NUM>) configured to measure a height of the lip (<NUM>) or the shim (<NUM>),
wherein the rail (<NUM>) is formed to be fixed long on one surface of the first die (<NUM>) in a longitudinal direction of the die coater (<NUM>), and
in that the sensor module (<NUM>) further comprises a position detection sensor (<NUM>) configured to detect a position of the lip (<NUM>) and
wherein the position detection sensor (<NUM>) comprises at least one of a fiber optic sensor, a photo sensor, a proximity sensor, or a vision sensor; andthe distance detection sensor (<NUM>) comprises at least one of a laser displacement sensor or an ultrasonic displacement sensor and
wherein the shim (<NUM>) comprises:at least one guide (<NUM>) configured to divide an internal space between the first die (<NUM>) and the second die (<NUM>) into a plurality of spaces; and
a base (<NUM>) configured to connect ends of the guide (<NUM>) to each other and extending in a longitudinal direction of the die coater (<NUM>),
wherein the position detection sensor (<NUM>) is configured to move along a first path (R1) in which the guide (<NUM>) is not present; and
the distance detection sensor (<NUM>) is configured to move along a second path (R2) in which the guide (<NUM>) is present.