a shim plate comprising at least one chamfered edge, and a slotted coating assembly comprising such a shim plate

Abstract

The invention relates to a mounting plate (20) for a slotted coating assembly (2), said mounting plate (20) comprising at least one chamfered edge. The invention also relates to a slotted coating assembly (2) comprising an ink reservoir (4), a slotted coating head (6) disposed downstream of the ink reservoir (4) and provided with an inlet (14), an outlet (16), one or more coating slots (18), and such a mounting plate (20) facing said coating slot(s) (18), and a substrate holder (8) disposed downstream of the slotted coating head (6) and designed to receive a substrate (12). (Figure for abbreviation: Figure 1)

Description

Title of the invention: a shim plate comprising at least one chamfered edge, and a slotted coating assembly comprising such a shim plate Technical field of the invention

[0001] The present invention relates to a shim plate, and a slotted coating assembly comprising an ink reservoir, a substrate holder and a slotted coating head provided with such a shim plate. Prior art

[0002] Solution coating techniques are used to deposit uniform films with thicknesses ranging from a few nanometers to a few micrometers over a large area. Among these coating techniques, slot coating is a well-known technique for applying thin films of solution, ink, hot melt, or extruded materials onto typically flat substrates such as glass, metal, paper, fabric, plastic, or metal foils. Such a slot coating process is notably used to manufacture electrodes or light-emitting diodes.

[0003] A slot coating assembly generally comprises an ink reservoir, a slot coating head located downstream of the ink reservoir, and a substrate holder located downstream of the slot coating head and designed to receive a substrate (an electrode substrate in this particular application). The substrate holder is, for example, a roller or flat type and may have a heating function. The slot coating head and the substrate holder are designed to move relative to each other. The slot coating head is provided with an inlet, an outlet, one or more coating slots, and a shim plate opposite said coating slot(s). The inlet of the slot coating head is connected to the ink reservoir, and the outlet of the slot coating head is located opposite the substrate on the substrate holder.The slotted coating head is designed to receive an inlet flow of ink at its inlet and to deliver an outlet flow of ink at its outlet, said outlet flow being intended to form a band of coating film on the substrate. The shim plate defines the outlet size of the slotted coating head and is used to create a band pattern.

[0004] However, a drawback of such a conventional slotted coating assembly is that the ink flow within the slotted coating head and its contact with the mounting plate produces a certain edge load ink on the ink outlet flow causes the edge load tolerance to become high and therefore leads to high scrap rates in the final manufactured product (the edge load tolerance is out of specification).

[0005] There is therefore a need for a shim plate for a slotted coating assembly, such a shim plate resulting in less ink edge load on the ink outlet flow, thus reducing scrap rates in the final manufactured product. Description of the invention

[0006] The object of the present invention is therefore to overcome the disadvantages of the prior art by proposing a shim plate for a slotted coating assembly, such a shim plate resulting in less ink edge load on the ink outlet flow, thus making it possible to reduce scrap rates in the final manufactured product.

[0007] According to a first aspect of the invention, a shim plate is proposed for a slotted coating assembly, said shim plate being intended to extend in relation to one or more coating slots of the slotted coating assembly, the shim plate comprising at least one chamfered edge.

[0008] The mounting plate thus designed and provided with at least one chamfered edge has the effect of slightly deflecting the ink flow at its edges. This reduces the edge load of the ink on the output ink flow, thereby reducing the edge load tolerance, and thus preventing bumps on the final product.

[0009] In a particular embodiment of the invention, the shoring plate has a rake-like shape and is provided with a main part and a plurality of branches, each branch protruding from said main part.

[0010] In a preferred embodiment, said at least one chamfered edge is provided on a free end of one of said branches. This facilitates contact between the at least one chamfered edge and the ink flow.

[0011] In a particular embodiment of the invention, said at least one chamfered edge connects two faces at right angles of the shim plate.

[0012] In a preferred embodiment, said at least one chamfered edge is a straight edge that forms an angle substantially equal to 45 degrees with said right-angled faces. This further reduces the edge load of the ink on the ink outlet flow, thereby reducing the edge load tolerance and thus preventing denting problems on the final product.

[0013] In another preferred embodiment, said at least one chamfered edge is such that the distance between said two faces at right angles, measured along a direction belonging to a plane parallel to one of the faces, is less than 1.5 mm, preferably approximately equal to 1 mm. This further reduces the edge load of the ink on the ink outlet flow, thus reducing the edge load tolerance, and thereby preventing bump problems on the final product.

[0014] The aforementioned embodiments can be combined.

[0015] According to a second aspect of the invention, a slotted coating assembly is proposed, comprising an ink reservoir, a slotted coating head disposed downstream of the ink reservoir and provided with an inlet, an outlet, one or more coating slot(s) and such a shim plate opposite said coating slot(s), and a substrate holder disposed downstream of the slotted coating head and designed to receive a substrate, the slotted coating head and the substrate holder being designed to be in relative motion with respect to each other, the inlet of said slotted coating head being connected to the ink reservoir, the outlet of said slotted coating head being disposed opposite the substrate on the substrate holder, said slotted coating head being designed to receive an inlet flow of ink at its inlet and to deliver an outlet flow of ink at the level of its release,The mounting plate is positioned in the slotted coating head such that at least one chamfered edge is in contact with the ink flow.

[0016] Thanks to the specific configuration of the mounting plate, the slotted coating assembly according to the invention reduces the edge load of the ink on the ink outlet. This reduces the edge load tolerance, thus preventing denting problems on the final product. Such a configuration significantly reduces scrap rates in the final manufactured product.

[0017] In a particular embodiment of the invention, the outlet of the slotted coating head is in the form of a single outlet lip.

[0018] In another particular embodiment of the invention, the dimensions of the chamfered edge are chosen according to the viscosity of the ink and / or the speed of movement of the substrate holder.

[0019] In another particular embodiment of the invention, the ink is such that its viscosity is substantially equal to 2200 cps ± 300 cps.

[0020] In another particular embodiment of the invention, the substrate carrier is such that its scrolling speed is substantially equal to 45 m / min. Brief description of the figures

[0021] Other advantages and features of the invention will become more readily apparent from the following description of a specific embodiment of the invention. The specific embodiment of the present invention is given by way of non-limiting example only, and is shown in the accompanying drawings, in which: • [Fig.1]: [Fig.1] is a schematic side view of a slot coating assembly according to an embodiment of the present invention, the slot coating assembly comprising an ink reservoir, a slot coating head, and a substrate holder, the slot coating head being provided with a shim plate; • [Fig. 2]: [Fig. 2] is a front view of the shim plate of [Fig. 1]; and • [Fig.3]: [Fig.3] is an enlarged front view showing a detail of the embodiment of the shim plate of [Fig.2].

[0022] The corresponding reference numbers refer to the same or corresponding parts in each of the figures. Figures 1 to 3 show an orthonormal XYZ frame. In the following description, the vertical direction denotes the direction parallel to the Z-axis, and the horizontal direction denotes any direction perpendicular to the vertical direction, in other words, any direction contained in the XY plane. Furthermore, the longitudinal direction A-A' denotes the principal extension direction of the shim plate. A transverse direction denotes any direction perpendicular to the longitudinal direction. In the particular embodiment illustrated in Figures 1 to 3, the longitudinal direction corresponds to the horizontal direction.

[0023] The words "downstream" and "upstream" are used in relation to the direction of movement of the ink. Detailed description of an implementation method

[0024] With reference to [Fig. 1], a slot coating assembly 2 comprises an ink reservoir 4, a slot coating head 6 and a substrate holder 8. Preferably, the slot coating assembly 2 further comprises a pumping system 10. In a preferred embodiment, the slot coating assembly 2 is intended to coat an electrode substrate 12 with one or more conductive strips (said conductive strips forming an active layer of the electrode).

[0025] The ink reservoir 4 contains ink and is preferably arranged above the slotted coating head 6 so as to supply it with ink. In the aforementioned preferred embodiment, the ink is intended to form said conductive strip(s). In a particular embodiment, the ink is such that its viscosity is substantially equal to 2200 cps ± 300 cps.

[0026] The slotted coating head 6 is arranged downstream of the ink reservoir 4 and is provided with an inlet 14, an outlet 16, one or more coating slots 18, and a positioning plate 20. Preferably, the slotted coating head 6 further includes an ink distribution chamber (not shown in the figures for clarity). In the embodiment shown in [Fig. 1], the head The slotted coating head 6 comprises a single coating slot 18. The coating slot 18 is in fluidic communication with the outlet 16 of the slotted coating head 6. The slotted coating head 6 and the substrate holder 8 are designed to move relative to each other. In a preferred embodiment shown in [Fig. 1], the slotted coating head 6 is permanently fixed to a frame (the latter not shown in the figures for clarity), and the substrate holder 8 is mounted to move relative to the slotted coating head 6 (as will be described in more detail later). In an alternative embodiment not shown in the figures, the substrate holder 8 can be permanently fixed to a frame, and the slotted coating head 6 can be mounted to move relative to the substrate holder 8.The slotted coating head 6 is designed to receive an inlet flow of ink at its inlet 14 and to deliver an outlet flow of ink at its outlet 16.

[0027] The inlet 14 of the slotted coating head 6 is connected to the ink reservoir 4. The outlet 16 of the slotted coating head 6 is arranged upstream of the substrate holder 8 and is further arranged opposite the substrate 12 on the substrate holder 8. Preferably, the outlet 16 of the slotted coating head 6 is in the form of a single outlet lip.

[0028] The shim plate 20 is positioned opposite the coating slot(s) 18 and is intended to define the output size and width of the ink bands in the band pattern to be coated onto the substrate 12. In the embodiment shown in Figures 1 to 3, the shim plate 20 is arranged in a vertical plane, i.e., in a plane parallel to the Z-axis, more precisely in the YZ plane. The shim plate 20 includes at least one chamfered edge 22. The shim plate 20 is arranged in the slotted coating head 6 such that at least one chamfered edge 22 is in contact with the ink flow.

[0029] In the particular embodiment shown in [Fig. 2], the shim plate 20 has a rake-like shape and is provided with a main part 20A and a plurality of arms 20B, namely four arms 20B in the embodiment shown in [Fig. 2]. Each arm 20B projects from the main part 20A of the shim plate 20. In the example of [Fig. 2], each arm 20B projects in a substantially vertical direction (i.e., along the Z-axis) when the shim plate 20 is installed within the slotted coating head 6. In this particular embodiment shown in [Fig. 2], the shim plate 20 comprises six chamfered edges 22, each chamfered edge 22 being provided on a free end of one of the arms 20B. More specifically, the two most lateral branches 20B each have a chamfered edge 22 at their free end, while that the two most central branches 20B each have at their free end two opposing chamfered edges 22.

[0030] As can be seen in [Fig. 2], each chamfered edge 22 preferably connects two right-angled faces of the shim plate 20. More preferably, each chamfered edge 22 is a straight edge that forms an angle of approximately 45 degrees with the two right-angled faces it connects. Even more preferably, and as shown in [Fig. 3], each chamfered edge 22 is such that the distance D1, D2 between the two right-angled faces it connects, measured along a direction belonging to a plane parallel to one of the faces (i.e., the XY plane or the XZ plane in the embodiment of Figures 2 and 3), is less than 1.5 mm, preferably approximately 1 mm (for a coated strip width in the micron range).These relative dimension proportions are unusual for such chamfered edges 22, as most known chamfered edges have one extension dimension larger than their other extension dimension (i.e., most of them form an angle other than 45 degrees with the two right-angled faces they join). Advantageously, this further reduces the edge load of the ink on the ink outlet, thereby reducing the edge load tolerance and preventing denting problems on the final product. The ink basis weight tolerance is thus improved, and scrap rates are advantageously reduced in the final manufactured product. Indeed, larger chamfered edges produce a lower edge load of the ink. In the mounting plate 20, the distance D1 of each chamfered edge 22 is advantageously equal to the distance D2, for example, approximately 1 mm.

[0031] Preferably, the dimensions of each chamfered edge are chosen according to the viscosity of the ink and / or the speed of the substrate carrier. In particular, the dimensions of each chamfered edge can be chosen according to the target ink loading profile.

[0032] The ink distribution chamber allows for uniform distribution of ink within the slotted coating head 6 and adequate flow of ink to the opening of the head.

[0033] The substrate carrier 8 is arranged downstream of the slotted coating head 6 and is designed to receive the substrate 12. In the embodiment shown in [Fig. 1], the substrate carrier 8 is a roller, which is mounted to rotate about a longitudinal axis (i.e., the horizontal X-axis in the embodiment of [Fig. 1]) to allow linear movement of the substrate 12 relative to the slotted coating head 6. The substrate carrier 8 in the form of a roller is, for example, such that its travel speed is approximately 45 m / min. In an alternative embodiment of The implementation not shown in the figures, the substrate holder 8 may be, for example, a flat type substrate holder and / or may have a heating function.

[0034] The pumping system 10 is designed to pump ink from the ink reservoir 4 into the slotted coating head 6 at predetermined flow rates.

[0035] The operation of the slotted coating assembly 2 according to the invention is described below.

[0036] Initially, the pumping system 10 pumps ink from the ink reservoir 4 into the slotted coating head 6 at predetermined flow rates. The ink is thus pumped into the slotted coating head 6, where it is distributed uniformly. The ink is then distributed by the ink distribution chamber within the slotted coating head 6, flows into contact with the mounting plate 20, then exits the coating slot(s) 18 and forms a meniscus between the coating slot outlet 16 and the substrate 12. The meniscus moves when the substrate holder 8 rotates, so as to deposit the ink onto the substrate 12. This allows the substrate 12 to be coated with one or more conductive strips made of ink.The quality of the coating depends on many parameters, such as the ink composition, the type of coating slot, and process variables (ink flow rate, coating speed, coating width, space between the slotted coating head 6 and the substrate 12).

[0037] The shimming plate 20 for a slotted coating assembly 2 according to the invention results in less edge load of the ink on the ink outlet flow, thus reducing scrap rates in the final manufactured product.

Claims

Demands

1. A shim plate (20) for a slotted coating assembly (2), said shim plate (20) being intended to extend opposite one or more coating slot(s) (18) of the slotted coating assembly (2), characterized in that the shim plate (20) comprises at least one chamfered edge (22).

2. A shoring plate (20) according to claim 1, wherein the shoring plate (20) has a rake-like shape and is provided with a main part (20A) and a plurality of branches (20B), each branch (20B) projecting from said main part (20A).

3. Shim plate (20) according to claim 2, wherein said at least one chamfered edge (22) is provided on a free end of one of said arms (20B).

4. Shim plate (20) according to any one of the preceding claims, wherein said at least one chamfered edge (22) connects two faces at right angles of the shimm plate (20).

5. Shim plate (20) according to claim 4, wherein said at least one chamfered edge (22) is a straight edge which forms an angle substantially equal to 45 degrees with said right-angled faces.

6. Shim plate (20) according to claim 4 or 5, wherein said at least one chamfered edge (22) is such that the distance (D1, D2) between said two right-angled faces, measured along a direction belonging to a plane parallel to one of the faces, is less than 1.5 mm, preferably substantially equal to 1 mm.

7. A slotted coating assembly (2) comprising an ink reservoir (4), a slotted coating head (6) disposed downstream of the ink reservoir (4) and having an inlet (14), an outlet (16), one or more coating slot(s) (18), and a shim plate (20) opposite said coating slot(s) (18), and a substrate holder (8) disposed downstream of the slotted coating head (6) and designed to receive a substrate (12), said shim plate (20) being a shim plate according to any one of the preceding claims, the slotted coating head (6) and the substrate holder (8) being designed to be in relative motion with respect to each other, the inlet (14) of said slotted coating head (6) being connected to the ink reservoir (4), the outlet (16) of said slotted coating head (6) being disposed opposite the substrate (12) on the carrier- substrate (8), said slotted coating head (6) being designed to receive an inlet flow of ink at its inlet (14) and to deliver an outlet flow of ink at its outlet (16), the shim plate (20) being arranged in the slotted coating head (6) such that at least one chamfered edge (22) is in contact with the ink flow.

8. Slotted coating assembly (2) according to claim 7, wherein the ink reservoir (4) contains an ink, the ink being such that its viscosity is equal to 2200 cps ± 300 cps.

9. Slotted coating assembly (2) according to any one of claims 7 or 8, wherein the substrate carrier (8) is such that its feed speed is equal to 45 m / min.

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