IEST Automated Electrode Powder Sampling System
IEST Automated Electrode Powder Sampling System
IEST Automated Electrode Powder Sampling System

IEST Automated Electrode Powder Sampling System(LEPS Series)

Introduction: The LEPS Series Automated Electrode Powder Sampling System is an advanced sample preparation system based on micrometer-level layer-by-layer scraping technology. It is designed to precisely peel off battery electrode coatings at different depths and regions to obtain highly accurate, structured samples. By replacing traditional manual scraping, the LEPS series eliminates operational inconsistencies, ensures precise depth control, and significantly improves the efficiency of powder sampling, ensuring analytically meaningful sample preparation for subsequent characterization techniques such as TGA, DSC, SEM, and XRD.

Features:

  • Precision Micro-Layered Scraping: Features a high-fidelity mechanical feed mechanism achieving an exceptional 0.1 μm scraping resolution and 1 μm depth accuracy, enabling flawless layered profiling of composite electrode coatings.
  • Closed-Loop Laser Thickness Tracking: Integrates an advanced, non-contact laser measurement system that provides real-time, closed-loop thickness monitoring throughout the dynamic scraping sequence to guarantee exact stratification.
  • Automated Vision & Tension Control: Combines a high-resolution vision module for rapid, fully automated blade calibration within 3 minutes with a constant-tension clamping fixture to lock down electrodes securely and repeatably.
  • Flexible Formats & QA/QC Traceability: Accommodates diverse electrode form factors with an adjustable sampling width (10–55 mm) while utilizing a fully logged parameter matrix to support robust QA/QC documentation and root-cause analysis.

Applications:

  • Cross-Sectional Compositional Gradient Mapping for Thick & Multi-Layer Electrodes
  • Transverse & Longitudinal Fixed-Point Sampling for Coating Micro-Uniformity Evaluation
  • Depth-Resolved Binder Migration (e.g., SBR) Quantification & Stratified TGA Profiling
  • Monitoring the stability of coating and calendering processes across different manufacturing batches.
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Description

1. Introduction

The LEPS Series Automatic Electrode Powder Scraper is a precision sampling instrument designed for lithium-ion battery electrode quality control and process validation. Leveraging micron-level layered scraping technology, the system enables accurate, reproducible delamination of electrode coatings at controlled depths and specific locations across the electrode sheet. By extracting structured powder samples from different coating depths and lateral positions, the LEPS series supports comprehensive compositional analysis, binder distribution profiling, and coating uniformity assessment. With automated tool alignment, optional non-contact closed-loop thickness measurement, and high-precision motion control (1 μm resolution), the LEPS platform eliminates the inconsistencies and risks inherent in manual scraping, ensuring traceable, reliable, and analytically meaningful sample preparation for subsequent characterization techniques such as TGA, DSC, SEM, and XRD.

2. Application Scenarios

IEST Automated Electrode Powder Sampling System-Application Scenarios IEST Automated Electrode Powder Sampling System-Application Scenarios (3)

  • Optimizing battery performance: Compositional analysis of thick/multi-layer coated electrodes.
  • Providing process validation or reverse analysis for overall electrode performance and quality.
  • Detecting SBR migration/anomalies as a routine quality control item for electrodes.

3. Conventional Method – Manual Powder Scraping

Process / laboratory personnel scrape the coating powder from the electrode surface using a ceramic blade, followed by thermogravimetric (TG) analysis.

Conventional Method - Manual Powder Scraping

Limitations of Traditional Methods (Manual Scraping & Tape Peeling):

Before automated systems, technicians relied on manual blade scraping or tape peeling to extract electrode powders. However, these manual methods introduce several critical deficiencies that compromise data integrity:

  • Low Efficiency & Labor-Intensive: Manual scraping is highly time-consuming and tedious, severely limiting laboratory throughput and sample preparation speed.

  • Inaccurate Depth Control: It is nearly impossible to precisely control the scraping depth by hand, leading to inaccurate, mixed, or unreliable depth-resolved sample information.

  • Lack of Traceability & Safety Risks: Manual operations are highly dependent on human technique, carry inherent operational risks, and completely lack data or result traceability.

  • Poor Inconsistent Uniformity: Weak scraping consistency between different operators or batches often renders subsequent analytical testing (such as TGA) highly unreliable and scientifically meaningless.

IEST Automated Electrode Powder Sampling System-5

4. IEST’s Innovative Method

  • Vision Module: High-precision vision module enabling fully automatic, fast, and precise blade calibration.

  • Electrode Thickness Measurement Module: Non-contact thickness measurement system enabling closed-loop thickness monitoring.

  • Precision Feed Mechanism: Accuracy up to 1μm; Resolution 0.1μm. Enables precise advancement and meticulous control over scraping depth.

  • Electrode Clamping Module: Constant tension to ensure sample loading consistency.

5. Functional Advantages

  • Precisely scrape coating thicknesses at the micrometer (μm) level.

  • Efficiently and uniformly complete powder sampling.

  • Guarantee the consistency of subsequent analytical testing.

Applications

1. Based on micron-level layered scraping technology, the system precisely delaminates electrode coatings at different depths and across different regions, obtaining structured powder samples.

1.1 Process Validation

Multi-Layer Coating Architecture Validation: As manufacturers adopt co-extrusion multi-layer die coating to optimize energy density, verifying interfacial mixing or compositional integrity becomes vital. The LEPS2000 allows localized compositional analysis to determine whether distinct functional layers maintain their target design boundaries.

Schematic of dual-layer slot-die coating on a moving substrate alongside particulate models illustrating gradient material layered-design validation and interface-targeted binder distribution.

  • Scenario: Samples obtained from different coating depths of the electrode are subjected to corresponding characterization techniques to derive compositional and structural information.

1.2 Uniformity Assessment

Stability monitoring of coating &calendering processes across

Schematic diagrams and cross-sectional SEM micrographs measuring electrode layer thickness consistency to evaluate micro-level coating uniformity across undercoated, single-sided, and double-sided lithium battery electrodes.

  • Scenario: Targeted scraping at predefined lateral and longitudinal positions, followed by compositional analysis, reveals the microscopic coating uniformity and consistency across the electrode sheet.

1.3 SBR Content Quality Control

Quantification of SBR/PVDF Stratification: By executing controlled 5 μm or 10 μm serial peeling steps from the surface down to the current collector, engineers can collect isolated powder fractions from precise spatial coordinates. Subjecting these layers to TGA profiles allows precise mapping of binder floating anomalies induced by aggressive drying temperatures.

Styrene-Butadiene Rubber (SBR)

  • Scenario: Powder samples obtained by scraping are analyzed via thermogravimetric analysis (TGA) to determine the styrene-butadiene rubber (SBR) content, identify abnormal SBR surface migration, and serve as a dedicated quality control protocol.

2. Application Case: CMC & SBR Content Analysis

Application Case CMC & SBR Content Analysis

Specifications

Parameter LEPS1000 LEPS2000
Dimensions & Weight Overall Dimensions 550*600*750 mm 550*600*750 mm
Net Weight Approx. 80 kg Approx. 80 kg
Vision-Assisted System Blade Calibration Automatic Automatic
Electrode Thickness Measurement Measurement Method N/A Non-contact closed-loop measurement
Sample Clamping & Motion Stage Travel Range 0-200/500/700 mm
(Optional & Adjustable)		 0-200/500/700 mm
(Selectable & Adjustable)
Tension / Clamping Force Fixed tension Fixed tension
Compatible Electrode Size 300/600/800*80mm 300/600/800*80mm
Blade & Carrier Platform Blade Material Tungsten carbide Tungsten Steel
Control Accuracy 1μm 1μm
Effective Sampling Width 10-55 mm (Optional) 10-55 mm (Optional)

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IEST Automated Electrode Powder Sampling System(LEPS Series)

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