Die coater

Abstract

According to exemplary embodiments, a die coater is provided. The die coater includes: a first die including a land portion and a manifold that has a predetermined depth from the land portion and is configured to accommodate an electrode slurry; a body shim coupled to the first die, wherein the body shim includes wings and a body arranged between the wings and connected to the wings, and the wings protrude from the body in a first direction and the body extends in a second direction perpendicular to the first direction; and a first spacer shim coupled to the first die and overlapping the manifold, wherein the first spacer shim includes first and second sidewalls defining an insulating flow path extending in the first direction, and the width of the insulating flow path in the second direction is variable.

Description

Die coater

[0001] The present invention relates to a die coater.

[0002] This application claims the benefit of priority to Republic of Korea Patent Application No. 10-2024-0048988, filed April 12, 2024, and Republic of Korea Patent Application No. 10-2025-0032482, filed March 13, 2025, all of which are incorporated herein by reference.

[0003] Unlike primary batteries, secondary batteries can be charged and discharged multiple times. They are widely used as a power source for various wireless devices, including handsets, laptops, and cordless vacuum cleaners. Recently, improved energy density and economies of scale have dramatically reduced the per-unit manufacturing cost of secondary batteries. Furthermore, as the range of battery electric vehicles (BEVs) has increased to match that of fuel-powered vehicles, the primary use of secondary batteries is shifting from mobile devices to mobility.

[0004] The electrodes of secondary batteries are the most important components in terms of energy density. Secondary battery electrodes can be formed through coating, roll pressing, drying, slitting, and notching processes. Among these, the coating process, which involves applying a coating material containing an active material onto a polarizing plate, can be performed using a die coater.

[0005] The technical problem to be achieved by the present invention is to provide a die coater with improved yield and reliability.

[0006] According to exemplary embodiments of the present invention for solving the above-described problem, a die coater is provided. The die coater comprises: a first die including a land portion and a manifold configured to receive electrode slurry having a predetermined depth from the land portion; a body shim coupled to the first die, the body shim including wings and a body interposed between the wings and connected to the wings, the wings protruding from the body in a first direction, the body extending in a second direction perpendicular to the first direction; and a first spacer shim coupled to the first die and overlapping the manifold, the first spacer shim including first and second sidewalls defining an insulating passage extending in the first direction, and a width of the insulating passage in the second direction being variable.

[0007] The first and second side walls are opposite to each other, the first side wall extends in the first direction, and the second side wall includes a step structure.

[0008] The second side wall includes a first portion extending in the first direction, a second portion connected to the first portion and extending in the second direction, a third portion connected to the second portion and extending in the first direction, and a fourth portion connected to the third portion and extending in the second direction.

[0009] The length of the second portion of the second side wall in the second direction and the length of the fourth portion of the second side wall in the second direction are different from each other.

[0010] The length of the second portion of the second side wall in the second direction is shorter than the length of the fourth portion of the second side wall in the second direction.

[0011] The length of the second portion of the second side wall in the second direction is in a range of 0.25 to 0.75 times the length of the fourth portion of the second side wall in the second direction.

[0012] The length of the first side wall in the first direction is smaller than the sum of the length of the first portion of the second side wall in the first direction and the length of the third portion of the second side wall in the first direction.

[0013] The fourth portion of the second side wall extends to an edge parallel to the first direction of the spacer core.

[0014] The distance in the second direction between the first side wall and the first portion of the second side wall is smaller than the distance in the second direction between the first side wall and the third portion of the second side wall.

[0015] The distance in the second direction between the first side wall and the first portion of the second side wall is equal to the length in the second direction of the fourth portion of the second side wall.

[0016] The die coater further comprises a second spacer core coupled to the first die and overlapping the manifold and spaced apart from the first spacer core in the second direction, wherein the second spacer core comprises first and second insulating passages, and the first insulating passage is identical to the insulating passage, and the second insulating passage is symmetrical with the first insulating passage.

[0017] The die coater further comprises a third spacer core coupled to the first die and overlapping the manifold and interposed between the first and second spacer cores, wherein the third spacer core comprises third and fourth insulating passages, and the third insulating passage is identical to the insulating passage, and the fourth insulating passage is symmetrical with the third insulating passage.

[0018] The first spacer core, the second spacer core, and the third spacer core are integral with the body core.

[0019] According to exemplary embodiments of the present invention, the perpendicularity of the edge profile of the electrode slurry provided by the die coater can be increased. Accordingly, the reliability and yield of the coating process using the die coater can be improved.

[0020] The effects that can be obtained from the exemplary embodiments of the present invention are not limited to the effects mentioned above, and other effects not mentioned can be clearly derived and understood by those skilled in the art to which the exemplary embodiments of the present disclosure pertain from the following description. In other words, unintended effects resulting from practicing the exemplary embodiments of the present disclosure can also be derived by those skilled in the art from the exemplary embodiments of the present disclosure.

[0021] Figure 1 illustrates a secondary battery manufacturing facility according to exemplary embodiments.

[0022] FIG. 2 is a side view including a cross-sectional side view of a die coater according to exemplary embodiments.

[0023] Figure 3 is an exploded perspective view illustrating a die coater according to exemplary embodiments.

[0024] Figure 4 shows a portion of Figure 3.

[0025] FIG. 5 is a plan view showing a spacer core according to exemplary embodiments.

[0026] Figure 6 shows a portion of Figure 5.

[0027] Figure 7 is a cross-sectional view taken along the cutting line 6I-6I' of Figure 6.

[0028] Figure 8 is a cross-sectional view taken along the cutting line 6II-6II' of Figure 6.

[0029] Figure 9 is a cross-sectional view taken along the cutting line 6III-6III' of Figure 6.

[0030] FIG. 10 is a plan view showing a spacer core according to exemplary embodiments.

[0031] FIG. 11 is a plan view showing a spacer core according to exemplary embodiments.

[0032] FIG. 12 is a perspective view showing a portion of a die coater according to exemplary embodiments.

[0033] Figure 13 is a graph showing the effectiveness of a die coater according to exemplary embodiments.

[0034] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. Prior to this, it should be noted that the terms and words used in this specification and claims should not be construed as limited to their conventional or dictionary meanings. Based on the principle that the inventor can appropriately define the concepts of terms to best explain his or her invention, they should be interpreted in a way that aligns with the technical spirit of the present invention.

[0035] Accordingly, the embodiments described in this specification and the configurations illustrated in the drawings are merely the most preferred embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that there may be various equivalents and modified examples that can replace them at the time of filing this application.

[0036] In addition, when describing the present invention, if it is determined that a detailed description of a related known configuration or function may obscure the gist of the present invention, the detailed description is omitted.

[0037] Since the embodiments of the present invention are provided to more fully explain the present invention to those skilled in the art, the shapes and sizes of components in the drawings may be exaggerated, omitted, or schematically illustrated for clearer explanation. Accordingly, the sizes and proportions of each component do not fully reflect the actual sizes or proportions.

[0038]

[0039] (Example 1)

[0040] Figure 1 illustrates a secondary battery manufacturing facility (10) according to exemplary embodiments.

[0041] According to exemplary embodiments, the secondary battery manufacturing facility (10) may include a die coater (100) and rolls (200). The die coater (100) may be configured to discharge a coating material. A portion of the die coater (100) from which the coating material is discharged may be referred to as a lip (100L). According to exemplary embodiments, the die coater (100) may be configured to coat a coating material on a current collector (SB). The coating material may include electrode slurry and insulating slurry. The die coater (100) may be configured to simultaneously provide the electrode slurry and the insulating slurry on the current collector (SB).

[0042] An electrode slurry can be used in the manufacture of an electrode of a secondary battery. The electrode slurry can include an electrode active material, a conductive material, a binder, and a solvent. The electrode slurry can be manufactured by dissolving the electrode active material, the conductive material, the binder, etc. in a solvent. The solvent can disperse the electrode active material, etc. The solvent can be an aqueous solvent or a non-aqueous solvent. The solvent can include any one of dimethyl sulfoxide (DMSO), isopropyl alcohol, N-methylpyrrolidone (NMP), acetone, water, and mixtures thereof. The amount of the solvent used can be determined based on the target viscosity of the electrode slurry. Parameters determining the amount of the solvent used include the coating thickness of the electrode slurry, the manufacturing yield, and the workability.

[0043] A cathode active material is a material capable of causing an electrochemical reaction. The cathode active material may be a lithium transition metal oxide. Examples of the cathode active material include layered compounds such as lithium cobalt oxide (LiCoO2) and lithium nickel oxide (LiNiO2) substituted with one or more transition metals; lithium manganese oxide substituted with one or more transition metals; chemical formula LiNi 1-y M y Lithium nickel oxide expressed as O2 (wherein, M is any one of Co, Mn, Al, Cu, Fe, Mg, B, Cr, Zn, and Ga, and 0.01≤y≤0.7); Li 1+z Ni 1 / 3 Co 1 / 3 Mn 1 / 3 O2, Li 1+zN i 0.4 Mn 0.4 Co 0.2 Li like O2 1+z Ni b Mn c Co 1-(b+c+d) M d O (2-e) A e (wherein, -0.5≤z≤0.5, 0.1≤b≤0.8, 0.1≤c≤0.8, 0≤d≤0.2, 0≤e≤0.2, b+c+d<1, M is any one of Al, Mg, Cr, Ti, Si, and Y, and A is any one of F, P, and Cl) lithium nickel cobalt manganese composite oxide; and chemical formula Li 1+x M 1-y M' y PO 4-z X z (wherein, M is a transition metal, more specifically, one of Fe, Mn, Co, and Ni, M' is one of Al, Mg, and Ti, X is one of F, S, and N, -0.5≤x≤+0.5, 0≤y≤0.5, and 0≤z≤0.1) and may include one of the olivine-based lithium metal phosphates.

[0044] The negative active material may include carbon, such as non-graphitizable carbon, graphitic carbon, etc. The negative active material may include, for example, Li x Fe2O3(0≤x≤1), LixWO2(0≤x≤1), Sn x Me 1-x Me' y O z (wherein Me is any one of Mn, Fe, Pb and Ge, and Me' is any one of Al, B, P, Si, elements of group 1, 2 and 3 of the periodic table and halogens; 0 <x≤1 이고; 1≤y≤3 이며; 1≤z≤8) 등의 금속 복합 산화물을 포함할 수 있다. 음극 활물질은, 예컨대, 리튬 금속; 리튬 합금; 규소계 합금; 및 주석계 합금 중 어느 하나를 포함할 수 있다. 음극 활물질은, 예컨대, SnO, SnO2, PbO, PbO2, Pb2O3, Pb3O4, Sb2O3, Sb2O4, Sb2O5, GeO, GeO2, Bi2O3, Bi2O4및 Bi2O5등의 금속 산화물을 포함할 수 있다. 음극 활물질은, 예컨대, 폴리아세틸렌 등의 도전성 고분자; Li-Co-Ni 계 재료 등을 포함할 수도 있다.

[0045] The conductive material can have conductivity without causing a chemical change in the secondary battery ultimately manufactured. The conductive material may include, for example, graphite such as natural graphite or artificial graphite; carbon black such as acetylene black, Ketjen black, channel black, furnace black, lamp black, and thermal black; conductive fibers such as carbon fiber or metal fiber; metal powders such as fluorocarbon, aluminum, and nickel powder; conductive whiskey such as zinc oxide or potassium titanate; conductive metal oxides such as titanium oxide; and polyphenylene derivatives.

[0046] The binder can enhance the bonding between the active material and the conductive material and the bonding strength to the electrode plate. The binder can include, for example, polyvinylidene fluoride, polyvinyl alcohol, carboxymethyl cellulose (CMC), starch, hydroxypropyl cellulose, regenerated cellulose, polyvinyl pyrrolidone, tetrafluoroethylene, polyethylene, polypropylene, ethylene-propylene-diene terpolymer (EPDM), sulfonated EPDM, styrene butylene rubber, fluoroelastomer, various copolymers, etc.

[0047] The thickness of the positive electrode current collector may be in the range of about 3 μm to about 500 μm. The positive electrode current collector may not cause chemical changes in the secondary battery to be ultimately manufactured and may have high conductivity. The positive electrode current collector may include, for example, any one of stainless steel, aluminum, nickel, titanium, calcined carbon, and aluminum. The positive electrode current collector may also include stainless steel surface-treated with carbon, nickel, titanium, silver, or the like. The surface of the positive electrode current collector may include a micro-roughened structure to increase the adhesion of the active material. The shape of the positive electrode current collector may include any one of a film, a sheet, a foil, a net, a porous material, a foam, and a non-woven fabric.

[0048] The thickness of the negative electrode current collector may be in the range of about 3 μm to about 500 μm. The negative electrode current collector may not cause chemical changes in the secondary battery to be ultimately manufactured and may have high conductivity. The negative electrode current collector may include any one of copper, stainless steel, aluminum, nickel, titanium, sintered carbon, and an aluminum-cadmium alloy. The negative electrode current collector may also include stainless steel surface-treated with carbon, nickel, titanium, silver, etc. The surface of the negative electrode current collector may include a micro-roughened structure to increase the adhesion of the active material. The shape of the negative electrode current collector may include any one of a film, a sheet, a foil, a net, a porous material, a foam, and a non-woven fabric.

[0049] The insulating slurry may include, for example, an insulating material, styrene butadiene rubber (SBR), a binder, a stabilizer, and a solvent. The insulating material may include a ceramic such as boehmite. The binder may include one of the materials described above with respect to the electrode slurry.

[0050] After the coating process, a roll press process, a drying process, a slitting process, and a notching process may be performed. The roll press process may be performed using a roll press device including pressure rolls. The roll press process can strengthen the bonding between the surface of the electrode and the active material. Accordingly, the movement of lithium ions within the electrode can be promoted, and the output and performance of the ultimately manufactured secondary battery can be improved.

[0051] The drying process of the electrode can be performed by supplying dry air into a drying chamber or supplying thermal energy to the electrode within the chamber, such as through infrared rays or high-temperature air. The drying process can improve the uniformity and reliability of the electrode by removing moisture from the electrode.

[0052] The slitting process separates an electrode into multiple electrodes with smaller widths in the transverse direction. The electrode can then be cut into a shape including tabs by a notching process.

[0053]

[0054] (Example 2)

[0055] FIG. 2 is a side view including a cross-sectional side view of a die coater (100) according to exemplary embodiments.

[0056] Fig. 3 is an exploded perspective view illustrating a die coater (100) according to exemplary embodiments. In Fig. 3, the second die (120) is omitted.

[0057] Figure 4 is a perspective view showing a part of Figure 3.

[0058] FIG. 5 is a plan view showing a spacer core (133) according to exemplary embodiments.

[0059] Referring to FIGS. 2 to 5, the die coater (100) may include a first die (110), a second die (120), and a core (130).

[0060] Hereinafter, the technical concept of the present invention will be described based on an embodiment in which the first die (110) and the second die (120) are separate elements, as described above. Those skilled in the art will readily be able to arrive at an embodiment in which the first die (110) and the second die (120) are integrated to form an integrated die, based on the description herein.

[0061] The first die (110) may include a manifold (111) and an electrode slurry supply path connected to the manifold (111). The electrode slurry may flow into the manifold (111) through the electrode slurry supply path. The manifold (111) may be a hollow space configured to receive the electrode slurry. After the electrode slurry fills the manifold (111), the electrode slurry may be discharged to the outside of the die coater (100). The electrode slurry may be discharged to the outside through slits defined by the shim (130) and the land portion (113) from the manifold (111).

[0062] The manifold (111) may have a well shape having a predetermined depth from the land portion (113). The manifold (111) may include an inclined surface, and thus, the electrode slurry may be stably discharged from the die coater (100).

[0063] The core (130) may be interposed between the first die (110) and the second die (120). The first die (110) may be in contact with the lower surface of the core (130). The second die (120) may be in contact with the upper surface of the core (130). The core (130) may include a body core (131) and spacer cores (133, 135, 137). The body core (131) may be referred to as a body part of the core (130), and the spacer cores (133, 135, 137) may each be referred to as a spacer part of the core (130).

[0064] The body core (131) may include a body (131B) and wings (131W). The body (131B) may extend in the Y direction. The body (131B) may be a plate having a width in the X direction that is smaller than a length in the Y direction. Here, the X direction is a direction in which the electrode slurry is discharged, and the Y direction may be substantially perpendicular to the X direction. The body core (131) may be substantially parallel to each of the X direction and the Y direction, and may be substantially perpendicular to the Z direction. The wings (131W) may be connected to an end of the body (131B) in the Y direction. The wings (131W) may protrude from the body (131B) in the X direction.

[0065] The body (131B) may include a plurality of grooves (131G). Each of the plurality of grooves (131G) may be located on one of the Y-direction-parallel sides of the body (131B) that is adjacent to the manifold (111) (e.g., overlapping the manifold (111)). Each of the plurality of grooves (131G) may be recessed inward from an edge parallel to the Y-direction of the body (131B) (i.e., toward another Y-direction-parallel edge).

[0066] A plurality of grooves (131G) may correspond to a plurality of spacer shims (133, 135, 137). The plurality of grooves (131G) may expose a portion of the first die (110). The plurality of spacer shims (133, 135, 137) may be partially inserted into a corresponding one of the plurality of grooves (131G). The plurality of spacer shims (133, 135, 137) may be fixed to the portion of the first die (110) exposed by the plurality of grooves (131G) by a method such as bolting.

[0067] According to exemplary embodiments, the Y-direction width of each of the plurality of grooves (131G) may be different from the Y-direction width of a corresponding one of the spacer shims (133, 135, 137). According to exemplary embodiments, the Y-direction width of each of the plurality of grooves (131G) may be larger than the Y-direction width of a corresponding one of the spacer shims (133, 135, 137). Accordingly, the plurality of grooves (131G) guide the coupling of the spacer shims (133, 135, 137) while providing the spacer shims (133, 135, 137) with a degree of freedom in the Y-direction, so that the positions of the spacer shims (133, 135, 137) can be precisely adjusted in the Y-direction.

[0068] According to exemplary embodiments, spacer cores (133, 135, 137) may be interposed between wings (131W) in the Y direction. According to exemplary embodiments, spacer cores (133, 135, 137) may overlap wings (131W) in the Y direction.

[0069] According to exemplary embodiments, the spacer shims (133) may be adjacent to the Y-direction edges of the shims (130). According to exemplary embodiments, the spacer shims (133) may be adjacent to the wings (131W). According to exemplary embodiments, the spacer shims (133) may be in contact with the wings (131W), but are not limited thereto. The spacer shims (133) may have a shape symmetrical to each other. The spacer shims (133) may be symmetrical about an axis parallel to the X-direction. Each of the spacer shims (133) may be referred to as an edge spacer shim or a first spacer shim.

[0070] According to exemplary embodiments, the spacer core (135) may be positioned at the center of the core (130) in the Y direction. According to exemplary embodiments, the spacer core (135) may be interposed between the spacer cores (133). The spacer core (135) may be referred to as a center spacer core or a second spacer core.

[0071] According to exemplary embodiments, spacer cores (137) may be interposed between spacer cores (133) and spacer cores (135). Each of the spacer cores (137) may be referred to as an intermediate spacer core or a third spacer core.

[0072] The spacer shims (133, 135, 137) can partially cover the manifold (111). The spacer shims (133, 135, 137) can overlap the manifold (111) in the Z direction. In FIG. 3, the spacer shims (133, 135, 137) can divide the manifold (111) into four regions, and accordingly, the die coater (100) can be configured to form four maintenance lanes through one coating process.

[0073] One skilled in the art will readily be able to arrive at die coaters configured to form various numbers of retention lanes, such as, for example, 1, 2, 8, 16, and 32, based on the description herein. For example, a die coater configured to form 8 retention lanes may include a shim assembly comprising 2 edge spacer shims, 1 center spacer shim, and 6 middle spacer shims.

[0074] Each of the spacer cores (133, 135, 137) can define one or more insulating passages. More specifically, each of the spacer cores (133) positioned at the edge of the core (130) can define one insulating passage, and each of the spacer cores (135, 137) interposed between the spacer cores (133) can define two insulating passages. Accordingly, an insulating slurry covering the electrode slurry can be provided at the edge of each holding portion.

[0075] The die coater (100) may further include core fixing devices (141, 143, 145) and core fixing pins (147).

[0076] The core fixing members (145) can fix the spacer cores (133) to the portion of the first die (110) exposed by the groove (131G). Each of the spacer cores (133) can include a fastening hole corresponding to the core fixing members (145) (i.e., into which the core fixing members (145) are inserted and through which the core fixing members (145) are penetrated).

[0077] The core fixing members (141) and the core fixing pins (143) may be partially inserted into the land portion (113) of the first die (110). The core fixing members (141) and the core fixing pins (143) may be configured to fix the spacer cores (133) to the land portion (113) of the first die (110). The core fixing members (141) may be, for example, bolts, but are not limited thereto.

[0078] The core fixing pins (143) may be, for example, bidirectional pins. Accordingly, the core fixing pins (143) may be configured to fix the second die (120) to the core (130) in addition to the first die (110). Each of the spacer cores (133) may include a fastening hole corresponding to the core fixators (141) and the core fixing pins (143) (i.e., the core fixators (141) and the core fixing pins (143) are inserted into, and are penetrated by the core fixators (141) and the core fixing pins (143).

[0079]

[0080] Figure 6 shows a portion (POR) of Figure 5.

[0081] Figure 7 is a cross-sectional view taken along the cutting line 6I-6I' of Figure 6.

[0082] Figure 8 is a cross-sectional view taken along the cutting line 6II-6II' of Figure 6.

[0083] Figure 9 is a cross-sectional view taken along the cutting line 6III-6III' of Figure 6.

[0084] Referring to FIGS. 5 to 9, the spacer core (133) may include a trench base (133B) defining an insulating flow path (133F) and first and second trench sidewalls (133S1, 133S2). The trench base (133B) may be substantially perpendicular to the Z direction. The first and second trench sidewalls (133S1, 133S2) may be substantially perpendicular to the trench base (133B), but are not limited thereto.

[0085] The insulating passage (133F) may provide a path for discharging the insulating slurry. The insulating passage (133F) may be connected to the inlet (133FI). The insulating passage (133F) may include a first portion (133FY), a corner portion (133FC), and a second portion (133FX).

[0086] The inlet (133FI) may have a wider width than other parts of the insulating flow path (133F), such as the first part (133FY), the corner part (133FC), and the second part (133FX), so that the insulating slurry can be stably supplied.

[0087] The first portion (133FY) may extend along the Y direction. The corner portion (133FC) may be interposed between the first portion (133FY) and the second portion (133FX). The corner portion (133FC) may be connected to each of the first portion (133FY) and the second portion (133FX) and may include a bent portion. The second portion (133FX) may extend along the X direction. The second portion (133FX) may extend to a lip (100L, see FIG. 1) of the die coater (100, see FIG. 1), and thus, the second portion (133FX) may also be referred to as a discharge path for the insulating slurry.

[0088] Unlike the example of FIG. 5, a bent portion connecting the second portion (122FX) and the inlet (133FI) may be provided instead of the first portion (133FY) and the corner portion (133FC). That is, the insulating flow path may not include a portion extending along the Y direction.

[0089] According to exemplary embodiments, the second portion (133FX) of the insulating conduit (133F) may have a variable width in the Y direction. According to exemplary embodiments, the second portion (133FX) of the insulating conduit (133F) may include a portion having a first width (WY1) and a portion having a second width (WY2) in the Y direction. The portion having the first width (WY1) may be closer to the lip (100L, see FIG. 1) than the portion having the second width (WY2). The portion having the first width (WY1) may be closer to the lip (100L, see FIG. 1) than the portion having the second width (WY2). The first width (WY1) and the second width (WY2) may be different from each other. The second width (WY2) may be greater than the first width (WY1).

[0090] The second side wall (133S2) may include a first portion (133S21) extending in the X direction, a second portion (133S22) extending in the Y direction, a third portion (133S23) extending in the X direction, and a fourth portion (133S24) extending in the Y direction.

[0091] The first width (WY1) may be a distance in the Y direction between the first side wall (133S1) and the first portion (133S21) of the second side wall (133S2). The second width (WY2) may be a distance in the Y direction between the first side wall (133S1) and the third portion (133S23) of the second side wall (133S2).

[0092] The second part (133S22) may be connected to the first part (133S21). The third part (133S23) may be connected to the second part (133S22). The fourth part (133S24) may be connected to the third part (133S23). Accordingly, the second side wall (133S2) may have a stepped structure composed of the first to fourth parts (133S21, 133S22, 133S23, 133S24).

[0093] According to exemplary embodiments, the first sidewall (133S1) may be closer to the center of the spacer core (133) than the second sidewall (133S2). According to exemplary embodiments, the first sidewall (133S1) may be closer to the edge (133EX) parallel to the X direction of the spacer core (133) than the second sidewall (133S2).

[0094] According to exemplary embodiments, the difference between the first width (WY1) and the second width (WY2) may be substantially equal to the length of the second portion (133S23) of the side wall (133S2). The fourth portion (133S24) of the side wall (133S2) may extend to the edge (133EX). Accordingly, some of the electrode slurry flowing from the manifold (111) to the land portion (113) may flow into the second portion (133FX) of the insulating conduit (133F), and before the electrode slurry and the insulating slurry are discharged, the electrode slurry and the insulating slurry may come into contact with each other. The difference (△LX) between the length of the first side wall (133S1) in the X direction and the length of the second side wall (133S2) in the X direction may be a distance over which the electrode slurry and the insulating slurry flow in a state of coming into contact.

[0095] According to exemplary embodiments, the length of the first side wall (133S1) in the X direction may be different from the length of the second side wall (133S2) in the X direction. According to exemplary embodiments, the length of the first side wall (133S1) in the X direction may be longer than the length of the second side wall (133S2) in the X direction. The length of the second side wall (133S2) in the X direction may be substantially equal to the sum of the length of the first portion (133S21) of the second side wall (133S2) in the X direction and the length (LX) of the third portion (133S23) of the second side wall (133S2) in the X direction. The length (LX) in the X direction of the third portion (133S23) of the second side wall (133S2) may have a length sufficient to allow the insulating slurry to flow in the Y direction as much as the length (LY1) in the Y direction of the second portion (133S22).

[0096] According to exemplary embodiments, the Y-direction length (LY1) of the second portion (133S22) of the second side wall (133S2) and the Y-direction length (LY2) of the fourth portion (133S24) may be different from each other. According to exemplary embodiments, the Y-direction length (LY1) of the second portion (133S22) of the second side wall (133S2) may be smaller than the Y-direction length (LY2) of the fourth portion (133S24) of the second side wall (133S2). According to exemplary embodiments, the Y-direction length (LY1) of the second portion (133S22) of the second side wall (133S2) may be in a range of 0.25 to 0.75 times the Y-direction length (LY2) of the fourth portion (133S24) of the second side wall (133S2).

[0097] The first width (WY1) may be different from the Y-direction length (LY1) of the second portion (133S22) of the second side wall (133S2). The first width (WY1) may be greater than the Y-direction length (LY1) of the second portion (133S22) of the second side wall (133S2). According to exemplary embodiments, the Y-direction length (LY1) of the second portion (133S22) of the second side wall (133S2) may be in a range of 0.25 to 0.75 times the first width (WY1). The first width (WY1) may be equal to, but is not limited to, the Y-direction length (LY2) of the fourth portion (133S24) of the second side wall (133S2).

[0098] According to exemplary embodiments, by adjusting the Y-direction length (LY1) of the second portion (133S22) of the second side wall (133S2) and the Y-direction length (LY2) of the fourth portion (133S24) of the second side wall (133S2), the width of the spreading of the insulating slurry and the width of the spreading of the electrode slurry in the second portion (133FX) of the insulating passage (133F) of the spacer shim (133) can be determined. The width of the spreading of the insulating slurry and the width of the spreading of the electrode slurry on the trench base (133B) can determine the position and size of the overlapping portion of the electrode slurry layer and the insulating slurry layer formed on the electrode current collector and the loading amount of the insulating slurry.

[0099] By forming a step structure composed of first to fourth portions (133S21, 133S22, 133S23, 133S24) on the second side wall (133S2), the width of the spreading of the insulating slurry and the width of the spreading of the electrode slurry on the trench base (133B) can be controlled, and in particular, by introducing the electrode slurry into the trench base (133B) of the spacer core (133) so that the insulating slurry and the electrode slurry come into contact before the insulating slurry is discharged, the squareness of the loading amount profile of the electrode slurry can be improved accordingly.

[0100] According to exemplary embodiments, the width of the trench base (133B) in the Y direction may be variable. According to exemplary embodiments, the trench base (133B) may include a portion having a first width (WY1) in the Y direction, a portion having a second width (WY2) in the Y direction, and a portion having a third width (WY3) in the Y direction.

[0101] The third width (WY3) may be different from the second width (WY2). The third width (WY3) may be greater than the second width (WY2). The third width (WY3) may be substantially equal to the sum of the second width (WY2) and the length (LY2) in the Y direction of the fourth portion (133S24) of the second side wall (133S2).

[0102] A portion of the trench base (133B) having the second width (WY2) may be closer to the lip (100L, see FIG. 1) than a portion of the trench base (133B) having the first width (WY1). A portion of the trench base (133B) having the second width (WY2) may be closer to the lip (100L, see FIG. 1) than a portion of the trench base (133B) having the first width (WY1). A portion of the trench base (133B) having the third width (WY3) may be closer to the lip (100L, see FIG. 1) than a portion of the trench base (133B) having the second width (WY2).

[0103]

[0104] Fig. 10 illustrates a spacer core (135) according to exemplary embodiments.

[0105] Referring to FIG. 10, the spacer core (135) may include an inlet (135FI) and first and second insulating passages (135F1, 135F2). The inlet (135FI) is substantially the same as the inlet (133FI) described with reference to FIGS. 5 to 9. The first insulating passage (135F1) is substantially the same as the insulating passage (133F) described with reference to FIGS. 5 to 9. The second insulating passage (135F2) may have a shape symmetrical to the first insulating passage (135F1).

[0106]

[0107] Fig. 11 illustrates a spacer core (137) according to exemplary embodiments.

[0108] Referring to FIG. 11, the spacer core (137) may include an inlet (137FI) and first and second insulating passages (137F1, 137F2). The inlet (137FI) is substantially the same as the inlet (133FI) described with reference to FIGS. 5 to 9. The first insulating passage (137F1) is substantially the same as the insulating passage (133F) described with reference to FIGS. 5 to 9. The second insulating passage (137F2) may have a shape symmetrical to the first insulating passage (137F1).

[0109]

[0110] FIG. 12 is a perspective view showing a portion of a die coater according to exemplary embodiments.

[0111] Referring to FIG. 12 together with FIG. 3, in the body shim (130), at least one of the spacer shims (133, 135, 137) may be integral with the body shim (131). That at least one of the spacer shims (133, 135, 137) is integral with the body shim (131) may refer to that at least one of the spacer shims (133, 135, 137) and the body shim (131) form a single piece or a single integrated structure. At least one of the spacer shims (133, 135, 137) and the body shim (131) may be manufactured together through the same process so that at least one of the spacer shims (133, 135, 137) is integral with the body shim (131). When at least one of the spacer shims (133, 135, 137) is integral with the body shim (131), the position of at least one of the spacer shims (133, 135, 137) can be determined by assembling the body shim (131) to the first die (110). In FIG. 12, the body shim (131) is illustrated as being integral with the spacer shim (133), but other spacer shims (135, 137) may also be integral with the body shim (131).

[0112] According to exemplary embodiments, the spacer cores (133, 135, 137) may all be integral with the body core (131).

[0113] According to exemplary embodiments, the spacer cores (133) may be integral with the body core (131), and the spacer cores (135, 137) may be separate from the body core (131).

[0114] According to exemplary embodiments, the spacer cores (137) may be integral with the body core (131), and the spacer cores (133, 135) may be separate from the body core (131).

[0115] According to exemplary embodiments, the spacer core (135) may be integral with the body core (131), and the spacer cores (133, 137) may be separate from the body core (131).

[0116]

[0117] FIG. 13 is a graph showing the effectiveness of a die coater (100, see FIG. 1) according to exemplary embodiments.

[0118] More specifically, FIG. 13 shows a transverse loading profile of an electrode slurry applied to a current collector (SB, see FIG. 1) by a die coater (100, see FIG. 1) and a transverse loading profile of an electrode slurry applied to a current collector by a die coater according to a conventional comparative example. In FIG. 13, the horizontal axis is expressed in arbitrary units and represents a transverse position. In addition, in FIG. 13, the vertical axis is expressed in arbitrary units and represents a loading amount.

[0119] Referring to FIGS. 1 and 13, it was confirmed that the perpendicularity of the transverse loading amount profile of the electrode slurry applied to the current collector (SB) by the die coater (100) was greatly improved compared to the conventional method.

[0120] The present invention has been described in more detail through drawings and examples. However, the configurations described in the drawings or examples described in this specification are merely embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that various equivalents and modified examples may exist as of the time of this application.

Claims

1. A first die including a land portion and a manifold configured to receive electrode slurry at a predetermined depth from the land portion; A body core coupled to the first die, wherein the body core includes wings and a body interposed between the wings and connected to the wings, the wings protruding from the body in a first direction, and the body extending in a second direction perpendicular to the first direction; and A first spacer core is coupled to the first die and overlaps the manifold, The first spacer core includes first and second side walls defining an insulating path extending in the first direction, and A die coater characterized in that the width of the second direction of the insulating filament is variable.

2. In paragraph 1, The first and second side walls are opposite to each other, The first side wall extends in the first direction, and A die coater, characterized in that the second side wall includes a step structure.

3. In paragraph 2, A die coater, characterized in that the second side wall includes a first portion extending in the first direction, a second portion connected to the first portion and extending in the second direction, a third portion connected to the second portion and extending in the first direction, and a fourth portion connected to the third portion and extending in the second direction.

4. In paragraph 3, A die coater, characterized in that the length of the second portion of the second side wall in the second direction and the length of the fourth portion of the second side wall in the second direction are different from each other.

5. In paragraph 3, A die coater, characterized in that the length of the second portion of the second side wall in the second direction is shorter than the length of the fourth portion of the second side wall in the second direction.

6. In paragraph 3, A die coater, characterized in that the length of the second portion of the second side wall in the second direction is in a range of 0.25 to 0.75 times the length of the fourth portion of the second side wall in the second direction.

7. In paragraph 3, A die coater, characterized in that the length of the first side wall in the first direction is smaller than the sum of the length of the first part of the second side wall in the first direction and the length of the third part of the second side wall in the first direction.

8. In paragraph 3, A die coater, characterized in that the fourth portion of the second side wall extends to an edge parallel to the first direction of the spacer core.

9. In paragraph 3, A die coater, characterized in that the distance in the second direction between the first side wall and the first portion of the second side wall is smaller than the distance in the second direction between the first side wall and the third portion of the second side wall.

10. In paragraph 3, A die coater, characterized in that the distance in the second direction between the first side wall and the first portion of the second side wall is equal to the length in the second direction of the fourth portion of the second side wall.

11. In paragraph 3, A second spacer core coupled to the first die and overlapping the manifold and spaced apart from the first spacer core in the second direction, The second spacer core further comprises first and second insulating filaments, and The above first insulation path is the same as the above insulation path, and A die coater, characterized in that the second insulating passage is symmetrical with the first insulating passage.

12. In paragraph 11, Further comprising a third spacer core coupled to the first die, overlapping the manifold, and interposed between the first and second spacer cores, The third spacer core includes third and fourth insulating filaments, and The third insulation euro is the same as the insulation euro, and A die coater, characterized in that the fourth insulating passage is symmetrical with the third insulating passage.

13. In paragraph 12, A die coater, characterized in that the first spacer core, the second spacer core, and the third spacer core are integrally formed with the body core.

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