Die coater and coating apparatus having same

Abstract

A die coater and a coating apparatus having same are disclosed. The die coater may comprise: a first die block which has a first storage part for accommodating a first coating material, and which extends in a first direction; a second die block which extends in the first direction so as to correspond to the first die block, and which covers the first storage part from the top thereof so as to seal same from the outside; a shim plate disposed between the first die block and the second die block so as to provide a first slot through which the first coating material flows in a second direction; and a deformation suppressor which is spaced apart from the first storage part in the second direction, and which is disposed in the first direction so as to traverse the first slot, thereby preventing deformation of the shim plate. Deformation of a coating guide is prevented such that the uniformity of a coating layer can be increased.

Description

Die coater and coating device equipped therewith

[0001] This application claims the benefit of priority from Republic of Korea Patent Application No. 10-2024-0108612, dated August 13, 2024, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to a die coater and a coating device having the same, and more particularly, to a die coater for manufacturing a plate for a secondary battery and a coating device having the same.

[0003] In general, a secondary battery is composed of an electrode assembly including a positive and negative electrode plates (hereinafter, “electrode plates”) and a separator, a battery can that accommodates the electrode assembly, and a sealing cap that is combined with the battery can to seal the electrode assembly inside and prevent leakage of the electrolyte.

[0004] At this time, the electrode plate is generally formed through a coating process of forming an electrode sheet by applying an active material on a conductive substrate and a cutting process of cutting the electrode sheet according to the size of the electrode assembly.

[0005] The performance and stability of a secondary battery are determined by the capacity of the active material, which in turn is determined by the thickness of the active material layer applied to the substrate. Therefore, it is desirable for the active material layer to be uniformly thick across the entire electrode plate. Accordingly, the coating process for applying the active material to the substrate is primarily performed by a die coater, which can reliably ensure uniform thickness of the active material layer.

[0006] In general, an active material slurry is supplied onto a substrate through a slot of a die coater to form an active material layer, and the substrate coated with the active material layer is cut into a certain size to form an electrode plate. At this time, since the slot is defined by a coating guide constituting the die coater, the shape characteristics of the active material layer may vary depending on the configuration of the coating guide. That is, the width and thickness of the active material layer can be obtained by adjusting the width and height of the coating guide.

[0007] However, the coating guide has a problem in that it is susceptible to deformation due to the geometric characteristics of the slender member, which has a relatively long length compared to its width. For example, when the die block and the shim plate are fastened with multiple bolts at the upper and lower portions of the shim plate, the coating guide, which has a slender shape, is frequently deformed by the bolt fastening force applied to the shim plate, thereby changing the width and thickness of the slot.

[0008] Changes in the shape of the slot reduce the uniformity in width and thickness of the active material layer formed on the substrate and cause capacitance deviations in the electrode plate.

[0009] Recently, interest has been growing in the multi-layer coating process, which forms multiple layers of active material along the width of a wide substrate with a width greater than its length, to improve the efficiency of the electrode manufacturing process. However, since the die coater used for this multi-layer coating process requires multiple coating guides positioned along the width of the substrate, deformation of the coating guides can lead to a decrease in the uniformity of the active material layer and an increase in the capacitance deviation of the electrode plate.

[0010] Accordingly, there is a need for a new die coater and a coating device equipped with the same that can improve the uniformity of the active material layer and reduce the capacity deviation of the electrode plate by suppressing deformation of the coating guide due to external force.

[0011] The present invention has been proposed to solve the above-described problems, and an object of the present invention is to provide a die coater having a deformation suppressing member capable of suppressing deformation of adjacent coating guides.

[0012] Another object of the present invention is to provide a coating device having a die coater as described above.

[0013] The technical objectives of the present invention are not limited to the objectives mentioned above, and other objectives and advantages of the present invention not mentioned above will become apparent through the following description and examples of the present invention. Furthermore, it will be appreciated that the objectives and advantages of the present invention can be realized and achieved by the means and combinations specifically pointed out in the claims.

[0014] According to one embodiment of the present invention for achieving the above object, a die coater may include a first die block having a first storage portion for accommodating a first coating material and extending in a first direction, a second die block extending in the first direction corresponding to the first die block and covering the first storage portion from the top to seal it from the outside, a shim plate disposed between the first die block and the second die block and providing a first slot through which the first coating material flows along a second direction perpendicular to the first direction, and a deformation prevention member disposed along the first direction so as to be spaced apart from the first storage portion along the second direction and cross the first slot and prevent deformation of the shim plate.

[0015] In one embodiment, the shim plate includes a base plate coupled to the first die block and the second die block along a third direction perpendicular to the first direction and the second direction and extending along the first direction, and two or more coating guides extending from the base plate along the second direction and spaced apart from each other to have a gap corresponding to the width of the first slot along the first direction to define the first slot, wherein the deformation prevention member and the coating guide can be in contact with the second die block simultaneously.

[0016] In one embodiment, the deformation prevention member may include at least one connecting rod having two ends connected to a pair of adjacent coating guides and extending along the first direction.

[0017] In one embodiment, the connecting rod may be provided in a three-dimensional shape having a rod upper surface positioned at the same level as the guide upper surface, which is the upper surface of the coating guide, and a rod lower surface spaced apart from the rod upper surface by the load thickness in the third direction.

[0018] In one embodiment, the load surface is formed as a flat surface parallel to the load upper surface at least in part, so that the load thickness can be uniform along the second direction at least in part of the connecting rod.

[0019] In one embodiment, the connecting rod cut along the third direction may have either a square cross-section or a trapezoidal cross-section.

[0020] In one embodiment, the load surface is formed as a curved surface having a constant curvature at least in part, so that the load thickness can be variable along the second direction.

[0021] In one embodiment, the connecting rod cut along the third direction may have either a semicircular cross-section or an arc cross-section.

[0022] In one embodiment, the load may have a protruding portion with a protruding portion and a recessed portion alternately aligned along the first direction.

[0023] In one embodiment, the deformation prevention member may include a connecting cross having a pair of inclined rods that are connected to adjacent coating guides at an angle to each other and positioned to intersect within the first slot.

[0024] In one embodiment, the deformation prevention member may include a connecting cover that is curvedly connected to the adjacent coating guide and has at least one bend within the first slot.

[0025] In one embodiment, the coating guides are arranged at regular intervals along the first direction, so that a plurality of slots spaced apart by the width of the coating guides can be aligned along the first direction.

[0026] In one embodiment, the second storage unit may further include a second storage unit that extends from an input terminal recessed from the upper surface of the shim plate and branched to a plurality of output terminals (OUT) respectively positioned in the plurality of coating guides and stores a second coating material, and a coupling protrusion that continuously protrudes from the lower surface of the second die block to correspond to the second storage unit and is coupled to the second storage unit to provide the second storage unit as a second slot that supplies the second coating material along the second direction.

[0027] In one embodiment, the second storage portion may include a defect groove that engages the engaging protrusion by a fit.

[0028] In one embodiment, the first coating material may include an active material slurry for a secondary battery, and the second coating material may include an insulating material.

[0029] In one embodiment, the distance from the edge of the first storage unit to the deformation suppressor may be in a range of 1 to 1.5 times the distance from the spray tip through which the first coating material is sprayed to the deformation suppressor.

[0030] According to another embodiment of the present invention for achieving the above object, a coating device may include a storage tank for storing a coating material, a supply module for supplying the coating material from the storage tank, and a die coater connected to the supply module for coating the coating material on a moving substrate. At this time, the die coater may include a first storage portion communicating with the supply module for receiving the coating material and a first die block extending in a first direction, a second die block extending in the first direction to correspond to the first die block and covering the first storage portion from the top to seal it from the outside, a shim plate disposed between the first die block and the second die block to provide a slot through which the coating material flows in a second direction perpendicular to the first direction, and a deformation suppressor disposed along the first direction so as to be spaced apart from the first storage portion in the second direction and to cross the slot to prevent deformation of the shim plate.

[0031] In one embodiment, the shim plate includes a base plate coupled to the first die block and the second die block along a third direction perpendicular to the first direction and the second direction and extending along the first direction, and two or more coating guides extending from the base plate along the second direction and spaced apart from each other to have a gap corresponding to the width of the slot along the first direction to define the slot, wherein the deformation prevention member and the coating guide can be in contact with the second die block simultaneously.

[0032] In one embodiment, the deformation prevention member may include at least one connecting rod having two ends connected to a pair of adjacent coating guides and extending along the first direction.

[0033] In one embodiment, the deformation prevention member may include a connecting cross having a pair of inclined rods that are connected to adjacent coating guides at an angle to each other and positioned to intersect within the slot.

[0034] According to the die coater and coating device having the same according to the present invention, deformation of a coating guide forming a coating layer can be suppressed by a deformation suppressor.

[0035] The deformation suppressor has a thickness smaller than the guide thickness and is positioned across the first slot. Therefore, deformation of the coating guide can be prevented by the bonding force that binds the first and second die blocks and the shim plate positioned therebetween.

[0036] In particular, since the flow space of the first slot is reduced by the volume of the deformation suppressor, the deformation suppressor can be provided as a connecting rod (410) having a rectangular shape, a trapezoidal shape, a semicircular shape, an arc shape, and a rough structure that can minimize the flow resistance to the first coating material.

[0037] Alternatively, the deformation suppressor may be provided as a connecting curve connecting the coating guides in a connecting cross or curved shape where a pair of connecting rods intersect.

[0038] Additionally, a second slot may be positioned between the shim plate and the second die block to spray a second coating material. The second coating material may be sprayed simultaneously with the first coating material, so that the first coating layer and the second coating layer may be alternately formed along the first direction.

[0039] However, the effects of the present invention are not limited to the effects described above, and additional technical effects not mentioned will be clearly understood by those skilled in the art from the description of the invention described below.

[0040] The drawings attached to this specification illustrate preferred embodiments of the present invention and, together with the detailed description of the invention described below, serve to explain the technical concepts of the present invention. Therefore, the present invention should not be construed as being limited to the matters described in the drawings.

[0041] FIG. 1 is a perspective view showing a die coater according to one embodiment of the present disclosure.

[0042] Figure 2 is an exploded perspective view of the die coater illustrated in Figure 1.

[0043] Fig. 3 is a cross-sectional view taken along line I-I' of the die coater illustrated in Fig. 1.

[0044] Fig. 4 is a cross-sectional view of the die coater illustrated in Fig. 1 taken along line II-II'.

[0045] Fig. 5 is a cross-sectional view of the die coater illustrated in Fig. 1 taken along the III-III' direction of Fig. 2.

[0046] Fig. 6 is a perspective view showing the upper part of the combined structure of the shim plate and the deformation suppressor illustrated in Fig. 2.

[0047] Fig. 7 is a perspective view showing the lower part of the joint structure illustrated in Fig. 6.

[0048] Fig. 8 is a perspective view showing a modified embodiment of the connecting rod illustrated in Fig. 6.

[0049] Fig. 9 is a perspective view showing another modified embodiment of the connecting rod illustrated in Fig. 6.

[0050] Fig. 10 is a cross-sectional view showing another modified embodiment of the connecting rod illustrated in Fig. 6.

[0051] Fig. 11 is a plan view showing another embodiment of the deformation suppressor illustrated in Fig. 1.

[0052] Fig. 12 is a plan view showing another embodiment of the deformation suppressor illustrated in Fig. 1.

[0053] Fig. 13 is a perspective view showing another embodiment of the shim plate illustrated in Fig. 2.

[0054] Fig. 14 is a cross-sectional view of the shim plate shown in Fig. 13 taken along line IV-IV'.

[0055] Fig. 15 is a cross-sectional view of the shim plate shown in Fig. 13 taken along the line V-V'.

[0056] FIG. 16 is a perspective view showing another embodiment of the second die block illustrated in FIG. 2.

[0057] Figures 17 and 18 are cross-sectional views showing the combined structure of the deformation die block illustrated in Figure 16 and the deformation shim plate illustrated in Figure 13.

[0058] FIG. 19 is a perspective view showing a coating device according to one embodiment of the present disclosure.

[0059] [Explanation of symbols]

[0060] 100: First die block 110: Long side member 120: Short side member 200: Second die block 210: Body 300: Shim plate 310: Base plate 320: Coating guide 321: Outermost guide 322: Coating guide 400: Deformation suppressor 410: Connecting rod 420: Connecting cross 430: Connecting curve 500: Die coater 600: Storage tank 700: Supply module 800: Rolling mill 1000: Coating device R1: First storage R2: Second storage S1: First slot S2: Second slot GT: Guide thickness RT: Rod thickness

[0061] The aforementioned objects, features, and advantages are described in detail below with reference to the accompanying drawings, so that those skilled in the art can easily practice the technical concepts of the present invention. In describing the present invention, if a detailed description of known technologies related to the present invention is judged to unnecessarily obscure the gist of the present invention, a detailed description thereof will be omitted. In the drawings, the same reference numerals indicate the same or similar components.

[0062] Although terms like "first" and "second" are used to describe various components, these components are not limited by these terms. These terms are used only to distinguish one component from another, and unless otherwise specified, a "first" component may also be a "second" component.

[0063] Throughout the specification, unless otherwise specifically stated, each element may be singular or plural.

[0064] Hereinafter, the phrase "any configuration is placed on (or below)" a component or "on (or below)" a component may mean that any configuration is placed in contact with the upper surface (or lower surface) of said component, and that other configurations may be interposed between said component and any configuration placed on (or below) said component.

[0065] Additionally, when it is described that a component is "connected," "coupled," or "connected" to another component, it should be understood that the components may be directly connected or connected to one another, but that other components may also be "interposed" between the components, or that each component may be "connected," "coupled," or "connected" through another component.

[0066] Hereinafter, singular expressions include plural expressions unless the context clearly dictates otherwise. In this application, terms such as "consist of" or "comprise" should not be construed to necessarily include all of the components or steps described in the specification, and should be construed to mean that some of the components or steps may not be included, or that additional components or steps may be included.

[0067] Throughout the specification, when we refer to "A and / or B", this means A, B, or A and B, unless otherwise stated, and when we refer to "C to D", this means C or more and D or less, unless otherwise stated.

[0068] The terminology used herein is for the purpose of describing embodiments of the present disclosure and is not intended to be limiting of the present disclosure.

[0069] Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the attached drawings.

[0070] Fig. 1 is a perspective view showing a die coater according to one embodiment of the present disclosure, and Fig. 2 is an exploded perspective view of the die coater illustrated in Fig. 1. Fig. 3 is a cross-sectional view of the die coater illustrated in Fig. 1 taken along line I-I', and Fig. 4 is a cross-sectional view of the die coater illustrated in Fig. 1 taken along line II-II'. Fig. 5 is a cross-sectional view of the die coater illustrated in Fig. 1 taken along line III-III' of Fig. 2.

[0071] Referring to FIGS. 1 to 5, a die coater (500) according to one embodiment of the present disclosure may include a first die block (100) and a second die block (200) positioned adjacently along a third direction (Z), which is a vertical direction, a shim plate (300) positioned between the first die block (100) and the second die block (200) to provide a first slot (S1) which is a discharge space through which a first coating material is discharged, and a deformation suppressor (400) positioned to span the first slot (S1) to suppress deformation of the shim plate (300).

[0072] As an example, the first die block (100) may be provided as a three-dimensional structure that stores the first coating material (CM1), which is a coating target material introduced from the outside.

[0073] For example, the first die block (100) may have a die length (L) extending along a first direction (X) perpendicular to a third direction (Z) and longer than the width of the coating layer on the substrate, and a die width (W) along a second direction (Y) perpendicular to the first direction (X) and the third direction (Z). At this time, the die length (L) may be configured to be sufficiently longer than the die width (W), so that the first die block (100) may have a rectangular shape.

[0074] In the present embodiment, the first die block (100) may include a bottom plate (B), a pair of long-side members (110) arranged on both peripheries of the bottom plate (B) so as to be spaced apart along the second direction (Y), and a pair of short-side members (120) arranged on both peripheries of the bottom plate (B) so as to be spaced apart along the bottom plate (B) and the first direction (X) and coupled with the pair of long-side members (110).

[0075] Accordingly, the space defined by the pair of long-side members (110), the pair of short-side members (120) and the floor plate (B) can be provided as a first storage unit (R1) capable of storing the first coating material (CM1). Therefore, the size of the first storage unit (R1) can be appropriately set by adjusting the length and spacing of the pair of long-side members (110) and the length and spacing of the pair of short-side members (120).

[0076] In the present embodiment, the bottom plate (B) is provided as a flat plate having sufficient strength, and the long side member (110) may be configured with a first long member (111) that is coupled to the front periphery of the bottom plate (B) located at the front of the die coater (500) and a second long member (112) that is coupled to the rear periphery of the bottom plate (B) located at the rear of the die coater (500) and spaced apart from the first long member (111). At this time, the size of the first storage unit (R1) can be adjusted by adjusting the positions of the first long member (111) and the second long member (112) that face each other.

[0077] The short-side member (120) may include a first end member (121) and a second end member (122) that are respectively combined with the long-side member (110) and the two sides of the floor plate (B) to define the first storage section (R1) and extend along the second direction (Y).

[0078] Although this embodiment discloses that the first storage portion (R1) is formed by combining a bottom plate (B), a pair of long-side members (110), and a pair of short-side members (120), this is exemplary, and it is obvious that the first storage portion (R1) can be formed by creating a recess having a predetermined depth in the upper surface of a single integral three-dimensional structure.

[0079] In particular, the first die block (100) is provided as a base block of the die coater (500), and a shim plate (300) is coupled to the upper surface of the first die block (100). Accordingly, the upper surface of the first die block (100) can be provided as a first coupling surface (101) that couples with the shim plate (300).

[0080] The first joining surface (101) is provided as a sufficiently flat surface so that the first storage portion (R1) can be sufficiently sealed from the surroundings when the shim plate (300) and the first die block (100) are joined. To this end, the upper surfaces of the long-side member (110) and the short-side member (120) can be processed through a flattening process to form sufficient flatness.

[0081] Accordingly, the first coating material (CM1) stored in the first storage unit (R1) inside the die coater (500) can be prevented from leaking between the shim plate (300) and the first die block (100).

[0082] Additionally, the first die block (100) may have a first inclined surface (102) that slopes downward from the first joining surface (101) at the front portion toward the rear portion. That is, a portion of the first member (111) and the bottom plate (B) may be inclinedly removed to form the first inclined surface (102), and the thickness of the front portion may be reduced compared to the original thickness of the first die block (100). The front portion of the first die block (100) having a relatively thin thickness may constitute a spray tip (DT) through which the first coating material (CM1) is sprayed from the die coater (500).

[0083] Accordingly, when the die coater (500) is placed adjacent to the substrate to be coated, the body area of ​​the first die block (100) excluding the spray tip (DT) can be spaced a certain distance from the substrate.

[0084] In this embodiment, the front part of the die coater (500) may be positioned adjacent to the substrate to discharge the first coating material (CM1), and the rear part may be positioned behind the front part along the second direction (Y).

[0085] For example, the first inclined surface (102) is provided to have an inclination angle (θ) of about 45° to about 60° from the first joining surface (101), and the front thickness (t), which is the thickness of the front portion having the first inclined surface (102), may be about 20% to 30% of the rear thickness (T), which is the thickness of the rear portion not having the first inclined surface (102).

[0086] A plurality of combining terminals (CT) are arranged at the rear end of the second member (112) and / or a pair of short-side members (110), so that the first die block (110) can be combined with the shim plate (300) and the second die block (200) using the combining terminals (CT). For example, the combining terminals (CT) may include a screw groove capable of accommodating a bolt. The second die block (200) and the shim plate (300) can be fixed to the first die block (100) via a fixing member (SM) fixed to the combining terminals (CT).

[0087] The first die block (100) may be composed of various materials as long as it has sufficient bonding strength to accommodate the first coating material (CM1) and withstand the bonding force applied from the fixing member (SM). For example, the first die block (100) may include a metal or plastic having sufficient bonding strength.

[0088] As an example, the second die block (200) may be configured as a rectangular three-dimensional structure that is positioned on top of the first die block (100) along the third direction (Z) and has a die length (L) along the first direction (X) and a die width (W) along the second direction (Y).

[0089] For example, the second die block (200) may have the same shape as the first die block (100) and may be arranged symmetrically with respect to the shim plate (300) with respect to the first die block (100).

[0090] Accordingly, the lower surface of the second die block (200) may be configured with a second coupling surface (201) having the same shape as the first coupling surface (101) and facing the first coupling surface (101). The second coupling surface (201) may be configured with a flat surface like the first coupling surface (101) and may seal the first storage portion (R1) from the outside while in contact with the shim plate (300).

[0091] Accordingly, the first coating material (CM1) stored in the first storage unit (R1) inside the die coater (500) can be prevented from leaking between the shim plate (300) and the second die block (200).

[0092] Additionally, the second die block (200) may have a second inclined surface (202) that is inclined upward from the second joining surface (201) toward the rear portion at the front portion and is symmetrical with the first inclined surface (102). That is, a portion of the front portion of the second die block (200) is inclinedly removed to form the second inclined surface (202), and the thickness of the front portion may be reduced compared to the original thickness of the second die block (200). The front portion of the second die block (200) with the reduced thickness may form a spray tip (DT) together with the front portion of the first die block (100).

[0093] Accordingly, when the die coater (500) is placed adjacent to the substrate to be coated, the body area of ​​the second die block (200) excluding the spray tip (DT) area can be separated from the substrate. The second inclined surface (202) has substantially the same configuration as the first inclined surface (102), except that it has a symmetrical shape of the first inclined surface (102) with respect to the shim plate (300).

[0094] In the present embodiment, unlike the first die block (100), the second die block (200) does not provide a storage space capable of storing a coating material. The second die block (200) is composed of a single die body (210) and can be in contact with the entire upper surface of the shim plate (300). The first coating material (CM1) stored in the first storage unit (R1) can be sealed from the outside by the second die block (200).

[0095] However, this is exemplary, and it is obvious that the second die block (200) may also be composed of a combination of multiple members, like the first die block (100).

[0096] A plurality of upper through holes (UPH) corresponding to each of the plurality of connecting sections (CT) provided in the first die block (100) may be arranged. A fixing member (SM) may be fixed to the connecting section (CT) by penetrating through the upper through hole (UPH) and the lower through hole (LPH) described below.

[0097] Accordingly, the first die block (100) and the second die block (200) can be joined to each other with the shim plate (300) between them.

[0098] As an example, the shim plate (300) may be placed between the first die block (100) and the second die block (200) to form a space corresponding to the thickness of the shim plate (300) as a first slot (S1). The first slot (S1) may be provided as a flow space in which slurry flows along the second direction (Y).

[0099] For example, the shim plate (300) may include a base plate (310) extending along a first direction (X) and two or more coating guides (320) extending from the base plate (310) along a second direction (Y) and spaced apart at regular intervals along the first direction (X).

[0100] A base plate (310) extending along the first direction (X) can be coupled with the first die block (100) and the second die block (200) along the third direction (Z). The first direction (X)

[0101] In the present embodiment, the base plate (310) is configured as a flat plate arranged to cover the rear ends of the second member (112) and the first and second short-side members (121, 122) connected to the second member (112), and a plurality of lower through holes (LPH) spaced at regular intervals along the first direction (X) can be arranged in the base plate (310). The plurality of lower through holes (LPH) are arranged to correspond to a plurality of connecting ends (CT), so that the base plate (310) can be fixed to the second member (112) by a plurality of fixing members (SM) that penetrate the plurality of upper through holes (UPH) and the plurality of lower through holes (LPH).

[0102] A plurality of coating guides (320) can extend from the base plate (310) in the second direction (Y) and be spaced apart from each other along the first direction (X) at intervals corresponding to the width of the first slot (S1) to define the first slot (S1).

[0103] In the present embodiment, the coating guide (320) is provided integrally with the base plate (310) and has the same guide thickness (GT) and extends in the second direction (Y) in a comb-like shape. Since the coating guide (320) of the shim plate (300) and the base plate (310) have the same thickness, the guide thickness (GT) may also be referred to as the shim thickness. In addition, the base upper surface (UBS), which is the upper surface of the base plate, is positioned at substantially the same level as the guide upper surface (UGS), which is the upper surface of the coating guide (320).

[0104] For example, the coating guide (320) may include a pair of outermost guides (321) protruding from both ends of the base plate (310) and positioned on top of the first and second short-side members (121, 122), and N (N is a positive integer) spaced guides (322) protruding from the base plate (310) so as to be equally spaced from each other between the pair of outermost guides (321). Accordingly, the die coater (500) may have (N+1) first slots (S1) between the pair of outermost guides (321).

[0105] A pair of outermost guides (321) extend from both ends of the first direction (X) base plate (310) along the second direction (Y), so that the first storage unit (R1) is surrounded in a 'U' shape by the base plate (310) and the pair of outermost guides (321).

[0106] The base plate (310) and a pair of outermost guides (321) are combined with the second member (112) and a pair of short-side members (120), and the shim plate (300) is fixed between the first die block (100) and the second die block (200).

[0107] The separation guide (322) protrudes from the base plate (310) in the second direction (Y) and extends across the first storage unit (R1). In the present embodiment, the separation guide (322) extends the same length as the pair of outermost guides (321), so that the coating guide (320) can extend uniformly along the second direction (Y).

[0108] A first storage unit (R1) extending along a first direction (X) is divided into a plurality of divided storage units by a separation guide (322), and the plurality of divided storage units are each connected to a plurality of first slots (S1) defined by the outermost guide (321) and the separation guide (322). That is, each divided storage unit of the first storage unit (R1) corresponds one-to-one to each first slot (S1).

[0109] Accordingly, the first coating material (CM1) stored in the first storage unit (R1) can be discharged to the outside of the die coater (500) through the first slot (S1) corresponding to the divided storage unit. Since the upper and lower surfaces of the base plate (310) and the coating guide (320) have flat surfaces, the shim plate (300) coupled between the first die block (100) and the second die block (200) can sufficiently seal the first storage unit (R1) from the outside of the die coater (500).

[0110] Accordingly, the slurry stored in the first storage unit (R1) can be discharged from the corresponding divided storage unit through each first slot (S1) to simultaneously form a plurality of active material layers that are distinct from each other on the substrate.

[0111] In this embodiment, the die coater (500) may be provided with three first slots (S1) by arranging two spacing guides (322). However, this is exemplary, and it is obvious that the spacing guides (322) may be appropriately arranged according to the number of active material layers to be individually formed on a single substrate.

[0112] As an example, the deformation suppressor (400) may be positioned to span the first slot (S1) along the first direction (X) and spaced apart from the first storage unit (R1) along the second direction (Y) to support the coating guide (320) and prevent deformation of the shim plate (300).

[0113] The deformation suppressor (400) is connected to the coating guide (320) that defines the first slot (S1) and can prevent deformation of the coating guide (320) due to external force during the fastening of the shim plate (300) or the discharge process of the first coating material (CM1).

[0114] Accordingly, the deformation suppressor (400) can be implemented in various configurations and structures as long as it can suppress deformation of the coating guide (320). However, since the deformation suppressor (400) is arranged across the first slot (S1), it can be configured to minimize the flow resistance of the first coating material (CM1) flowing along the first slot (S1).

[0115] Fig. 6 is a perspective view showing the upper part of the combined structure of the shim plate and the deformation suppressor shown in Fig. 2, and Fig. 7 is a perspective view showing the lower part of the combined structure shown in Fig. 6.

[0116] As shown in FIGS. 6 and 7, the deformation suppressor (400) may include a pair of adjacent coating guides (320) and a linear connecting rod (410) connected at both ends.

[0117] The connecting rod (410) has a rectangular parallelepiped shape that is positioned at the same level as the guide upper surface (UGS) and has a solid rod upper surface (411) and a flat rod lower surface (412) spaced apart from the rod upper surface (411) by the rod thickness (RT) along the third direction (Z), so that the connecting rod (410) and the coating guide (320) can be in contact with the second die block (200) at the same time.

[0118] That is, the connecting rod (410) is positioned to span the upper portion of the coating guide (320) across the first slot (S1), and the guide upper surface (UGS) and the rod upper surface (411) are positioned to form the same plane so as to be in contact with the lower surface of the second die block (200).

[0119] The lower surface of the second die block (200), the upper surface of the guide (UGS) and the upper surface of the rod (411) are configured as flat surfaces, so that the first storage section (R1) can be sufficiently sealed by contact between the connecting rod (410), the coating guide (320) and the second die block (200).

[0120] Since the connecting rod (410) is positioned across the first slot (S1), flow resistance may be generated while the first coating material (CM1) flows. Accordingly, the connecting rod (410) needs to be provided so as to minimize flow resistance within the first slot (S1).

[0121] For example, the connecting rod (410) can be set to have a rod thickness (RT) that is smaller than the guide thickness (GT) and uniform along the first direction (X). Accordingly, the lower surface of the rod (412) is configured as a flat surface parallel to the upper surface of the rod (411) and is arranged to have a constant step with respect to the lower surface of the guide (LGS), which is the lower surface of the coating guide (320), so that the first coating material (CM1) can flow to the lower portion of the connecting rod (410).

[0122] In the present embodiment, the rod thickness (RT) may be set to have a range of 20% to 40% of the guide thickness (GT). If the rod thickness (RT) is less than 20% of the guide thickness (GT), it may be difficult for the connecting rod (410) to have a rigidity sufficient to prevent deformation of the coating guide (320). In addition, if the rod thickness (RT) is greater than 40% of the guide thickness (GT), the flow resistance of the first coating material (CM1) due to the connecting rod (410) may increase, thereby lowering the coating efficiency of the die coater (500).

[0123] At this time, the load width (RW), which is the width of the connecting rod (410), can be set to minimize the volume reduction of the first slot (S1) by the connecting rod (410) within a range that does not damage the deformation suppression function for the coating guide (320).

[0124] For example, the load width (RW) can be set to have a range of about 20% to about 30% of the guide length (GL), which is the length of the coating guide (320). If the load width (RW) exceeds 30% of the guide length (GL), the volume of the first slot (S1) decreases by a volume corresponding to the load width (RW) and the load thickness (RT) in each first slot (S1), which may reduce the coating efficiency of the die coater (500). If it is less than 20%, it is difficult for the connecting rod (410) to secure sufficient rigidity, making it difficult to suppress deformation of the coating guide (320).

[0125] In particular, the connecting rod (410) is positioned at a constant distance from the edge of the injection tip (DT) and the first storage portion (R1) so as to stably maintain the flow stream at the start and end points of the flow of the first coating material (CM1).

[0126] When the connecting rod (410) is positioned adjacent to the first storage unit (R1), the total supply flow rate of the first coating material (CM1) through the first slot (S1) is limited by the connecting rod (410), so that the coating efficiency may decrease. In addition, when the connecting rod (410) is positioned adjacent to the spray tip (DT), the spraying speed of the first coating material (CM1) may increase due to the reduction in the flow cross-sectional area by the connecting rod (410), which may make it difficult to control the coating.

[0127] In the present embodiment, the connecting rod (410) may be positioned so that the distance from the edge of the first storage unit (R1) to the connecting rod (410) is about 1 to 1.5 times the distance from the injection tip (DT) to the connecting rod (410).

[0128] In this embodiment, the connecting rod (410) has a rectangular parallelepiped shape in which the upper surface (411) of the rod and the lower surface (412) of the rod are parallel, but this is exemplary and may be provided in various shapes as long as the flow resistance of the connecting rod (410) can be minimized.

[0129] Fig. 8 is a perspective view showing a modified embodiment of the connecting rod illustrated in Fig. 6.

[0130] Referring to FIG. 8, the first deformation connecting rod (410a) may be configured so that the load surface (412) has a smaller size than the load upper surface (411), and may be provided with a load inclined surface (413) that connects the load surface (412) and the load upper surface (411) at an angle.

[0131] At this time, the load slope (413) adjacent to the first storage unit (R1) can gradually reduce the flow area along the flow direction of the first coating material (CM1) to reduce the rate of change in the flow rate. Accordingly, the flow resistance of the first coating material (CM1) in the first slot (S1) due to the first deformation connecting rod (410a) can be reduced.

[0132] In addition, the load slope (413) adjacent to the injection tip (DT) can gradually expand the flow area along the flow direction of the first coating material (CM1), thereby maintaining the flow characteristics of the first coating material (CM1) relatively uniform due to the rapid expansion of the flow area.

[0133] Accordingly, the uniformity of the flow characteristics of the first coating material (CM1) in the first slot (S1) can be improved and the flow resistance can be reduced.

[0134] Fig. 9 is a perspective view showing another modified embodiment of the connecting rod illustrated in Fig. 6.

[0135] Referring to FIG. 9, the second deformed connecting rod (410b) can be deformed into a lower curved surface (414) by forming a continuous curved shape with the load side (412). Accordingly, the second deformed connecting rod (410b) is configured as a lower curved surface (414) with a continuous side and bottom, and the rod thickness (RT) can be variably set along the lower curved surface (414).

[0136] The lower curved surface (414) is provided as a curved shape having a constant curvature or a variable curvature along the second direction (Y), and the rod thickness (RT) may vary depending on the position along the second direction (Y). For example, the cross-section of the second deformable connecting rod (410b) along the second direction (Y) may include a semicircular surface or an arc surface formed as a part of a semicircle.

[0137] Accordingly, the volume of the first slot (S1) can be continuously reduced and then continuously restored along the second direction (Y) by the second deformation connecting rod (410b), thereby continuously changing the flow characteristics of the first coating material (CM1) along the second direction (Y). That is, the flow of the first coating material (CM1) inside the first slot (S1) can be transformed into a streamlined stream to minimize flow resistance.

[0138] Accordingly, deformation of the coating guide (320) can be suppressed while minimizing the flow resistance caused by the second deformation connecting rod (410b) arranged across the first slot (S1).

[0139] Fig. 10 is a cross-sectional view showing another modified embodiment of the connecting rod illustrated in Fig. 6.

[0140] Referring to FIG. 10, the third modified connecting rod (410c) may be provided with a plurality of grooves (G) that are sunken in the load surface (412) and arranged at regular intervals along the first direction (X). Accordingly, the third modified connecting rod (410c) may be provided with a protruding portion (GP) in which a load ridge (RG) and a load protrusion (RP) are alternately aligned at the bottom.

[0141] The first coating material (CM1) flowing from the first storage unit (R1) into the first slot (S1) has a flow resistance increased due to a reduced flow space caused by the third deformation connecting rod (410c), but the first coating material (CM1) can be allowed to flow by partially securing the flow space through the rod member (RG). Accordingly, the flow resistance in the first slot (S1) can be relatively reduced.

[0142] Therefore, the shape of the groove (G) arranged in the load case (412) or the spacing between adjacent grooves (G) along the first direction (X) can be appropriately adjusted according to the flow characteristics and distribution of the first coating material (CM1) inside the first slot (S1).

[0143] Fig. 11 is a plan view showing another embodiment of the deformation suppressor illustrated in Fig. 1.

[0144] Referring to FIG. 11, a deformation suppressor (400) according to another embodiment of the present disclosure may include a connecting cross (420) that is connected to adjacent coating guides (320) at an angle across the first slot (S1) and intersects within the first slot (S1).

[0145] The connecting cross (420) may include a first inclined rod (421) and a second inclined rod (422), which are respectively connected to adjacent coating guides (320) so as to intersect with each other. For example, the first inclined rod (421) may connect the adjacent coating guide (320) downward from the left to the right, and the second inclined rod (422) may connect the adjacent coating guide (320) upward from the left to the right. Accordingly, the first inclined rod (421) and the second inclined rod (422) may form a connecting cross (420) that intersects with each other at the center of the first slot (S1).

[0146] At this time, the slope width (Ws) of the first slope load (421) and the second slope load (422) is configured to be less than half the load width (RW) of the connecting load (410), thereby minimizing the reduction in the flow space of the first slot (S1) due to the connecting cross (420) and enhancing the deformation suppression effect on the coating guide (320).

[0147] In particular, the slope width (Ws) and shape of the first slope rod (421) and the second slope rod (422) can be variously set so as to efficiently suppress deformation of the coating guide (320) according to the distribution of external force applied to the shim plate (300).

[0148] Accordingly, the first inclined rod (421) and the second inclined rod (422) may have different inclined widths (Ws) and may have different substructures depending on the flow characteristics of the first coating material (CM1).

[0149] For example, the first inclined rod (421) and the second inclined rod (422) may have substantially the same configuration as the connecting rod (410) illustrated in FIGS. 6 to 10, respectively.

[0150] Fig. 12 is a plan view showing another embodiment of the deformation suppressor illustrated in Fig. 1.

[0151] Referring to FIG. 12, a deformation suppressor (400) according to another embodiment of the present disclosure may include a connecting curve (430) that connects adjacent coating guides (320) across the first slot (S1) in a streamlined shape.

[0152] The connecting curve (430) is provided in the form of a curved rod that crosses the first slot (S1) by connecting adjacent coating guides (320) in a curved shape. Accordingly, the connecting curve (430) may include at least one bend (431) along the flow direction of the first coating material (CM1).

[0153] The flow resistance region for the first coating material (CM1) by the connecting rod (410) occurs linearly along the width of the first slot (S1), but the flow resistance region for the first coating material (CM1) by the connecting curve (430) may occur in a parabolic shape along the width of the first slot (S1). Accordingly, the flow resistance for the first coating material (CM1) can be distributed, thereby maintaining the flow of the first coating material (CM1) more uniformly within the first slot (S1).

[0154] In the present embodiment, the inflection portion (431) is provided as a concave inflection portion protruding toward the injection tip (DT), but may also be provided as a convex inflection portion protruding toward the first storage portion (R1) depending on the flow characteristics in the first slot (S1). That is, the connecting curve (430) may be provided in a curved shape protruding toward the first storage portion (R1) or the injection tip (DT).

[0155] Additionally, although not shown, it is obvious that the inflection portion (431) may be provided in a wave shape in which the concave inflection portion and the convex inflection portion are alternately arranged along the first direction (X).

[0156] Referring again to FIGS. 1 to 5, the first coating material (CM1) may include an electrode slurry containing an active material for manufacturing a secondary battery. The electrode slurry is a mixture of an active material, a conductive material, and a binder. A slurry containing a positive electrode active material may be provided as a positive electrode slurry, and a slurry containing a negative electrode active material may be provided as a negative electrode slurry.

[0157] By means of a coating device as described below, the positive electrode slurry is coated on the positive electrode substrate to form a positive electrode plate, and the negative electrode slurry is coated on the negative electrode substrate to form a negative electrode plate.

[0158] The positive electrode slurry may be provided as a mixture of a positive electrode active material, a binder, and / or a conductive agent. The content of the positive electrode active material may be 90 wt% to 99.5 wt% based on 100 wt% of the positive electrode slurry, and the contents of the binder and the conductive agent may each be 0.5 wt% to 5 wt% based on 100 wt% of the positive electrode slurry.

[0159] The binder serves to adhere the positive electrode active material particles well to each other and to the substrate that constitutes the current collector well. Representative examples of binders include, but are not limited to, polyvinyl alcohol, carboxymethyl cellulose, hydroxypropyl cellulose, diacetyl cellulose, polyvinyl chloride, carboxylated polyvinyl chloride, polyvinyl fluoride, polymers containing ethylene oxide, polyvinyl pyrrolidone, polyurethane, polytetrafluoroethylene, polyvinylidene fluoride, polyethylene, polypropylene, styrene-butadiene rubber, (meth)acrylated styrene-butadiene rubber, epoxy resin, (meth)acrylic resin, polyester resin, nylon, etc.

[0160] Conductive materials are used to provide conductivity to electrodes, and any material that does not cause chemical changes and is electronically conductive can be used in the battery being constructed. Examples of conductive materials include carbon-based materials such as natural graphite, artificial graphite, carbon black, acetylene black, Ketjen black, carbon fibers, carbon nanofibers, and carbon nanotubes; metallic materials containing copper, nickel, aluminum, and silver in the form of metal powder or metal fibers; conductive polymers such as polyphenylene derivatives; or mixtures thereof.

[0161] The cathode active material may be composed of a compound capable of reversible intercalation and deintercalation of lithium (lithiated intercalation compound). Specifically, at least one compound oxide of lithium and a metal selected from cobalt, manganese, nickel, and combinations thereof may be used. The compound oxide may be a lithium transition metal compound oxide, and specific examples thereof include lithium nickel-based oxide, lithium cobalt-based oxide, lithium manganese-based oxide, lithium iron phosphate-based compound, cobalt-free nickel-manganese-based oxide, or combinations thereof.

[0162] For example, the positive electrode active material may include a compound represented by any one of the following chemical formulas: Li a A 1-b X b O 2-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05); Li a Mn 2-b X b O 4-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05); Li a Ni 1-b-c Co b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2); Li a Ni 1-b-c Mn b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2); Li a Ni b Co c L 1 d G e O2(0.90≤a≤1.8, 0≤b≤0.9, 0≤c≤0.5, 0≤d≤0.5, 0≤e≤0.1); Li a NiG bO2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a CoG b O2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn 1-b G b O2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn2G b O4(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn 1-g G g PO4(0.90≤a≤1.8, 0≤g≤0.5); Li (3-f) Fe2(PO4)3(0≤f≤2); Li a FePO4(0.90≤a≤1.8).

[0163] In the above chemical formula, A is Ni, Co, Mn, or a combination thereof, X is Al, Ni, Co, Mn, Cr, Fe, Mg, Sr, V, a rare earth element, or a combination thereof, D is O, F, S, P, or a combination thereof, G is Al, Cr, Mn, Fe, Mg, La, Ce, Sr, V, or a combination thereof, and L 1 is Mn, Al or a combination thereof.

[0164] As an example, the cathode active material may be a high-nickel cathode active material in which the nickel content is 80 mol% or more, 85 mol% or more, 90 mol% or more, 91 mol% or more, or 94 mol% or more and 99 mol% or less, based on 100 mol% of metals excluding lithium in the lithium transition metal composite oxide. The high-nickel cathode active material can realize high capacity and thus can be applied to high-capacity, high-density lithium secondary batteries.

[0165] The negative electrode slurry may be provided as a mixture of a negative electrode active material, a binder, and / or a conductive material. For example, the negative electrode active material layer may comprise 90 to 99 wt% of the negative electrode active material, 0.5 to 5 wt% of the binder, and 0 to 5 wt% of the conductive material.

[0166] The binder serves to adhere the negative active material particles to each other and to the current collector. For example, the binder may include a non-aqueous binder, an aqueous binder, or a combination thereof.

[0167] Non-aqueous binders include polyvinyl chloride, carboxylated polyvinyl chloride, polyvinyl fluoride, ethylene propylene copolymer, polystyrene, polyurethane, polytetrafluoroethylene, polyvinylidene fluoride, polyethylene, polypropylene, polyamideimide, polyimide, or combinations thereof.

[0168] The aqueous binder may be selected from styrene-butadiene rubber, (meth)acrylated styrene-butadiene rubber, (meth)acrylonitrile-butadiene rubber, (meth)acrylic rubber, butyl rubber, fluoroelastomer, polyethylene oxide, polyvinylpyrrolidone, polyepichlorohydrin, polyphosphazene, poly(meth)acrylonitrile, ethylene propylene diene copolymer, polyvinylpyridine, chlorosulfonated polyethylene, latex, polyester resin, (meth)acrylic resin, phenol resin, epoxy resin, polyvinyl alcohol, and combinations thereof.

[0169] When using an aqueous binder as the cathode binder, a cellulose-based compound capable of imparting viscosity may be further included. The cellulose-based compound may be a mixture of one or more of carboxymethyl cellulose, hydroxypropylmethyl cellulose, methyl cellulose, or an alkali metal salt thereof. The alkali metal may be Na, K, or Li.

[0170] Conductive materials are used to impart conductivity to electrodes, and any material that does not cause chemical changes and is electronically conductive can be used in the battery being constructed. Specific examples include carbon-based materials such as natural graphite, artificial graphite, carbon black, acetylene black, Ketjen black, carbon fibers, carbon nanofibers, and carbon nanotubes; metal-based materials in the form of metal powders or metal fibers, including copper, nickel, aluminum, and silver; conductive polymers such as polyphenylene derivatives; and mixtures thereof.

[0171] The negative electrode active material includes a material capable of reversibly intercalating / deintercalating lithium ions, lithium metal, an alloy of lithium metal, a material capable of doping and dedoping lithium, or a transition metal oxide.

[0172] The material capable of reversibly intercalating / deintercalating the lithium ions may include a carbon-based negative electrode active material, for example, crystalline carbon, amorphous carbon, or a combination thereof. Examples of the crystalline carbon include graphite such as natural graphite or artificial graphite in an amorphous, plate-like, flake-like, spherical, or fibrous form, and examples of the amorphous carbon include soft carbon or hard carbon, mesophase pitch carbide, calcined coke, and the like.

[0173] The above lithium metal alloy may be an alloy of lithium and a metal selected from Na, K, Rb, Cs, Fr, Be, Mg, Ca, Sr, Si, Sb, Pb, In, Zn, Ba, Ra, Ge, Al, and Sn.

[0174] As the material capable of doping and dedoping the lithium, a Si-based negative electrode active material or a Sn-based negative electrode active material may be used. The Si-based negative electrode active material may include at least one of silicon, a silicon-carbon composite, SiOx (0 < x < 2), a Si-Q alloy (wherein Q is selected from alkali metals, alkaline earth metals, Group 13 elements, Group 14 elements (excluding Si), Group 15 elements, Group 16 elements, transition metals, rare earth elements, and combinations thereof), and combinations thereof. The Sn-based negative electrode active material may include at least one of Sn, SnO2, a Sn-based alloy, and combinations thereof.

[0175] The silicon-carbon composite may be a composite of silicon and amorphous carbon. As an example, the silicon-carbon composite may be in the form of silicon particles and amorphous carbon coated on the surface of the silicon particles. For example, the composite may include secondary particles (cores) in which silicon primary particles are assembled, and an amorphous carbon coating layer (shell) positioned on the surface of the secondary particles. The amorphous carbon may also be positioned between the silicon primary particles, so that the silicon primary particles may be coated with the amorphous carbon. The secondary particles may be dispersed in the amorphous carbon matrix.

[0176] The silicon-carbon composite may further comprise crystalline carbon. For example, the silicon-carbon composite may comprise a core comprising crystalline carbon and silicon particles and an amorphous carbon coating layer positioned on the surface of the core.

[0177] The Si-based negative electrode active material or the Sn-based negative electrode active material can be used in combination with the carbon-based negative electrode active material.

[0178] In the present embodiment, the electrode slurry can be provided as a cathode slurry and anode slurry for a lithium battery.

[0179] In this embodiment, a die coater (500) is disclosed for coating a first coating material (CM1) on a substrate, but a second slot (S2) may be arranged on a shim plate (300) to simultaneously coat a second coating material (CM2) together with the first coating material (CM1) on the substrate.

[0180] Fig. 13 is a perspective view showing another embodiment of the shim plate illustrated in Fig. 2. Fig. 14 is a cross-sectional view of the shim plate illustrated in Fig. 13 taken along line IV-IV', and Fig. 15 is a cross-sectional view of the shim plate illustrated in Fig. 13 taken along line V-V'.

[0181] Referring to FIGS. 13 to 15, a deformation shim plate (300a) according to another embodiment of the present disclosure may be provided with a second storage unit (R2) for supplying a second coating material (CM2) to the upper surface.

[0182] The modified shim plate (300a) illustrated in FIGS. 13 to 15 has substantially the same configuration as the shim plate (300) illustrated in FIGS. 1 to 5, except that it further includes a second storage unit (R2). Accordingly, in FIGS. 13 to 15, the same reference numerals are used for the same components as in FIGS. 1 to 5, and further detailed descriptions of the same components are omitted.

[0183] For example, the second storage portion (R2) may be provided as a recessed area having a predetermined depth in the base upper surface (UBS) and the guide upper surface (UGS). In the present embodiment, the guide upper surface (UGS) corresponding to a portion of the spaced guide (322) and the outermost guide (321) and the base upper surface (UBS) corresponding to the base plate (310) adjacent to the spaced guide (322) may be recessed to a predetermined depth to form the second storage portion (R2).

[0184] Accordingly, the second storage unit (R2) can be continuously connected from the output terminal (OUT) provided at the end of the separation guide (322) and the outermost guide (321) to the input terminal (IN) provided at the end of the base plate (310) to provide a second slot (S2 of FIG. 17) through which the second coating material (CM2) flows.

[0185] Since the base upper surface (UBS) and the guide upper surface (UGS) are positioned at substantially the same level, the second storage unit (R2) can be provided in a uniform line at the same level. Accordingly, the second coating material (CM2) can flow uniformly in the second slot (S2).

[0186] In particular, the output terminal (OUT) is arranged so that each spaced guide (322) is positioned separately from the outermost guide (321) and the input terminal (IN) is positioned singly on the base plate (310), so that the second storage unit (R2) can be provided as a branch line branching from the input terminal (IN) to each output terminal (OUT).

[0187] Accordingly, the second coating material (CM2) introduced into the input terminal (IN) can be branched into each separation guide (322) and simultaneously sprayed onto the substrate through a plurality of output terminals (OUT).

[0188] At this time, the input width (Win), which is the width of the input terminal (IN), can be configured to be sufficiently larger than the output width (Wout), which is the width of the output terminal (OUT), so that the second coating material (CM2) introduced from the input terminal (IN) can be sprayed at a uniform flow rate from the output terminal (OUT) after branching.

[0189] Although this embodiment discloses a structure in which the second storage unit (R2) is arranged only in a part of the coating guide (320), it is obvious that the second storage unit (R2) can be arranged in all of the coating guides (320) including all of the outermost guides (321) depending on the characteristics and requirements of the electrode plate.

[0190] In addition, the thickness of the coating layer formed on the substrate can be controlled by appropriately adjusting the height of the second storage unit (R2). For example, the height (h) of the second storage unit (R2) can be set to correspond to the difference between the guide thickness (GT) and the rod thickness (RT), so that the first coating material (CM1) and the second coating material (CM2) can be coated on the substrate with the same thickness.

[0191] In the present embodiment, the second storage unit (R2) may be recessed into two stages and may be provided with an upper step (US). The upper step (US) may be provided as a coupling groove (CR) that is coupled with a coupling protrusion (250) provided in the second die block (200a) according to another embodiment of the present disclosure.

[0192] FIG. 16 is a perspective view showing another embodiment of the second die block illustrated in FIG. 2.

[0193] Referring to FIG. 16, a second die block according to another embodiment of the present disclosure, a modified die block (200a), may be provided with a coupling protrusion (250) that seals a second storage portion (R2) on a second coupling surface (201) and provides a second slot (S2).

[0194] The modified die block (200) illustrated in FIG. 16 has substantially the same configuration as the second die block (200) illustrated in FIGS. 1 to 5 except that it further includes a coupling protrusion (250). Accordingly, in FIG. 16, the same reference numerals are used for the same components as in FIGS. 1 to 5, and further detailed descriptions of the same components are omitted.

[0195] For example, the coupling protrusion (250) may be provided as a line structure protruding from the second coupling surface (201) to correspond to the second storage portion (R2) provided in the deformation shim plate (300a).

[0196] In particular, the coupling protrusion (250) protrudes from the second coupling surface (201) to have a protrusion length (PL) corresponding to the depth of the coupling groove (CR). Accordingly, when the deformation die block (200a) and the deformation shim plate (300a) are coupled, the coupling protrusion (250) can be inserted into the coupling groove (CR) and coupled by a fit.

[0197] Figures 17 and 18 are cross-sectional views showing the joint structure of the modified die block shown in Figure 16 and the modified shim plate shown in Figure 13. Figure 17 shows the joint structure at the output terminal (OUT), and Figure 18 shows the joint structure at the input terminal (IN).

[0198] As illustrated in FIGS. 17 and 18, the second storage unit (R2) may be sealed from the outside by a coupling protrusion (250) and provided as a second slot (S2). The second slot (S2) may be configured as a branch structure having a single input terminal (IN) located on the base plate (310) and a plurality of output terminals (OUT) each located at at least a portion of an end of the coating guide (320).

[0199] The second coating material (CM2) supplied to the input terminal (IN) can flow from the outside along the sealed second slot (S2) and be sprayed through the output terminal (OUT). At this time, the first coating material (CM1) and the second coating material (CM2) can be sprayed simultaneously, so that the first coating layer (30 in FIG. 19) formed by the first coating material (CM1) and the second coating layer (40 in FIG. 19) formed by the second coating material (CM2) can be formed simultaneously.

[0200] In addition, since the output terminals (OUT) are individually arranged on each of the spaced guides (322) and a portion of the outermost guide (321), the second coating layer (40) can be positioned along one side of the first coating layer (30).

[0201] For example, the second coating material (CM2) may include an insulating material. Accordingly, the second coating layer (C2) coated with the second coating material (CM2) may serve as an insulating coating layer. The insulating coating layer can prevent short circuit defects in which the positive and negative plates come into contact with each other due to thermal shrinkage of the separator during a subsequent electrode assembly process.

[0202] According to the die coater (500) as described above, a connecting rod (410) may be provided that is connected to a coating guide (320) that defines a first slot (S1) through which a first coating material (CM1) flows and prevents deformation of the coating guide (320).

[0203] The connecting rod (410) has a rod thickness (RT) smaller than the guide thickness (GT) and is positioned across the first slot (S1). Therefore, the coating guide (320) can be prevented from being deformed by the bonding force that binds the first and second die blocks and the shim plate (300) positioned therebetween.

[0204] In particular, since the flow space of the first slot (S1) is reduced by the volume of the connecting rod (410), the connecting rod (410) may have a rectangular, trapezoidal, or arc-shaped cross-section and may have a rough structure along the length direction of the connecting rod (410) so as to minimize the flow resistance to the first coating material (CM1).

[0205] Additionally, a second slot (S2) may be arranged between the shim plate (300) and the second die block (200) to spray the second coating material (CM2). Accordingly, the second coating material (CM2) may be sprayed simultaneously with the first coating material (CM1), so that the first coating layer and the second coating layer may be alternately arranged.

[0206] FIG. 19 is a perspective view showing a coating device according to one embodiment of the present disclosure.

[0207] Referring to FIG. 19, a coating device (1000) according to one embodiment of the present disclosure may include a storage tank (600) for storing a coating material, a supply module (700) for supplying a coating material, and a die coater (500) for spraying a coating material onto a substrate (20).

[0208] In the present embodiment, the die coater (500) has substantially the same configuration as the die coater (500) described with reference to FIGS. 1 to 18. Accordingly, in FIG. 19, the same reference numerals are used for the same components as in FIGS. 1 to 18, and further detailed descriptions of the same components are omitted.

[0209] As an example, a storage tank (600) may be disposed outside the die coater (500) to supply a coating material to the die coater (500). In the present embodiment, the storage tank (600) may include a first tank (610) for storing a first coating material (CM1) and a second tank (620) for storing a second coating material (CM2). The storage tank (600) may have various structures as long as it has rigidity and strength that can stably store the coating material.

[0210] For example, the first tank (610) can store electrode slurry in which electrode active materials, binders, and / or conductive materials are mixed and manufactured through a mixing process, and the second tank (620) can store insulating materials. In particular, the first tank (610) can be divided into an anode tank that stores anode slurry and a cathode tank that stores cathode slurry.

[0211] As an example, the supply module (700) may be disposed between the storage tank (600) and the die coater (500) to supply the coating material to the die coater (500). For example, the supply module (700) may include a first supply (710) for supplying a first coating material (CM1) and a second supply (720) for supplying a second coating material (CM2).

[0212] The first supply unit (710) may include a first pipe (T1) connected to the first tank (610), a first supply pump (711) connected to the first pipe (T1) to supply a first coating material (CM1), and a first driving motor (712) driving the first supply pump (711).

[0213] The first pipe (T1) is connected from the first tank (610) to the first storage (R1) of the die coater (500), and the first coating material (CM1) is supplied to the first storage (R1) by the first supply pump (711) operated by the first driving motor (712).

[0214] The second pipe (T2) is connected from the second tank (620) to the second storage (R2) of the die coater (500), and the second coating material (CM2) is supplied to the second storage (R2) by the second supply pump (721) operated by the second driving motor (722).

[0215] In particular, the driving conditions of the first driving motor (712) and the second driving motor (722) are controlled by a coating control module (not shown) to control the flow rate of the coating material supplied to the first storage unit (R1) and the second storage unit (R2) of the die coater (500).

[0216] The first coating material (CM1) and the second coating material (CM2) supplied to the die coater (500) can be sprayed onto a moving substrate (20) to form a first coating layer (30) and a second coating layer (30), respectively. The die coater (500) can be positioned to face the substrate (20) on the side or upper portion of the substrate (20) to spray the first coating material (CM1) and the second coating material (CM2) simultaneously.

[0217] The first coating material (CM1) introduced into the first storage unit (R1) can be sprayed onto the substrate (20) through the first slot (S1), and the second coating material (CM2) introduced into the second storage unit (R2) can be sprayed onto the substrate through the second slot (S2).

[0218] At this time, the substrate (20) may be composed of an appropriate material depending on the polarity of the first coating material (CM1). For example, if the first coating material (CM1) is composed of a positive slurry, the substrate (20) may be composed of an aluminum thin plate, and if the second coating material (CM2) is composed of a negative slurry, the substrate (20) may be composed of a copper thin plate.

[0219] The first coating layer (30) is formed on the substrate (20) so as to have a width corresponding to the width of the first slot (S1) defined by adjacent coating guides (320). In addition, a second slot (S2) is arranged adjacent to the first slot (S1) in the coating guide (320) defining the first slot (S1), and the second coating material (CM2) is sprayed simultaneously with the first coating material (CM1), so that the second coating layer (40) can be formed adjacent to the first coating layer (30) on the substrate (20).

[0220] In particular, the die coater (500) may be configured such that a pair of outermost guides (321) and a plurality of spaced guides (322) are arranged along the first direction (X), so that one more first slot (S1) than the number of intermediate guides (321) may be arranged. Accordingly, the die coater (500) may simultaneously form a plurality of first coating layers (30) corresponding to each of the first slots (S1) on the substrate (20).

[0221] In particular, a second coating layer (40) composed of an insulating layer is formed simultaneously along each periphery of the first coating layer (30) to prevent short circuits of the electrode plates due to damage to the separator during a subsequent assembly process or use of the secondary battery. In other words, a plurality of electrode plates capable of preventing short circuits can be coated simultaneously on a single substrate (20).

[0222] When the first coating layer (30) and the second coating layer (40) are formed on the substrate (20), the coating process can be completed by compressing the first and second coating layers (30, 40) to a set thickness through a rolling mill (800).

[0223] Accordingly, the electrode density of the first and second coating layers (30, 40) formed on the substrate (20) and the contact force with the substrate can be increased. In particular, by adding an appropriate compound density to the first coating layer (30), an appropriate electrode density can be maintained to increase battery output while reducing electrolyte penetration resistance during the assembly process.

[0224] In particular, a shim plate (300) provided between a first die block (100) and a second die block (200) to provide a first slot (S1) is configured with a base plate (310) that is coupled to the first die block (100) and the second die block (200) along a third direction (Z) and extends along a first direction (X), and a plurality of coating guides (320) that extend from the base plate (310) along a second direction (Y) and are spaced apart from each other to have a gap corresponding to the width of the first slot (S1) along the first direction (X) to define the first slot (S1), and deformation of the coating guides (320) can be prevented by a deformation suppressor (400).

[0225] The deformation suppressor (400) is connected to the adjacent coating guide (320) across the first slot (S1), thereby preventing the coating guide (320) from being deformed during the process of combining the first die block (100) and the second die block (200) with the shim plate (300). Accordingly, the width of the first coating layer (30) coated along the first slot (S1) can be maintained uniformly.

[0226] In particular, the deformation suppressor (400) and the coating guide (320) are set to have the same level as the upper surface so as to contact the second die block (200) simultaneously, and the first coating material (CM1) can flow through the first slot (S1) through the lower part of the deformation suppressor (400).

[0227] At this time, the deformation suppressor (400) is configured with a structure capable of minimizing flow resistance, such as a connecting rod (410), a connecting cross (420), and a connecting curve (430) as shown in FIGS. 6 to 12, so as to reduce the flow resistance through the first slot (S1) while maintaining the width of the first coating layer (30) uniform.

[0228] Accordingly, the shape characteristics of multiple coating layers formed in a multi-layer structure on a single substrate (20) can be uniformly maintained.

[0229] In this embodiment, a die coater (500) is disclosed that coats a first coating material (CM1) and a second coating material (CM2) simultaneously, but if necessary, only the first coating material (CM1) may be coated.

[0230] For example, the second tank (620), the second feeder (720), and the second slot (S2) may be selectively provided to the die coater (500). Alternatively, the operations of the second tank (620) and the second feeder (720) may be selectively stopped to form only the first coating layer (30) on the substrate (20).

[0231] In this embodiment, the die coater (500) discloses a configuration for applying electrode slurry on a substrate that is a current collector to form an electrode plate, but this is exemplary, and it is obvious that it can be applied to various fields if a set material is applied to a substrate using a shim plate disposed between a pair of dies.

[0232] According to the die coater (500) and the coating device (1000) having the same as described above, deformation of the coating guide (320) forming the coating layer can be prevented by the deformation suppressor (400).

[0233] The deformation suppressor (400) has a thickness smaller than the guide thickness (GT) and is positioned across the first slot (S1). Therefore, the coating guide (320) can be prevented from being deformed by the bonding force that binds the first and second die blocks (100, 200) and the shim plate (300) positioned therebetween.

[0234] In particular, since the flow space of the first slot (S1) is reduced by the volume of the deformation suppressor (400), the deformation suppressor (400) can be provided as a connecting rod (410) having a rectangular shape, a trapezoidal shape, a semicircular shape, an arc shape, and a rough structure that can minimize the flow resistance to the first coating material (CM1).

[0235] Alternatively, the deformation suppressor (400) may be provided as a connecting cross (420) in which a pair of connecting rods (410) intersect, or a connecting curve (430) connecting the coating guide (320) in a curved shape.

[0236] Additionally, a second slot (S2) may be arranged between the shim plate (300) and the second die block (200) to spray a second coating material (CM2). The second coating material (CM2) may be sprayed simultaneously with the first coating material (CM1) so that the first coating layer and the second coating layer may be alternately formed along the first direction (X).

[0237] It should be understood that the above-described embodiments are illustrative in all respects and not restrictive, and the scope of the present invention will be determined by the claims that follow, rather than by the detailed description set forth above. Furthermore, the meaning and scope of the claims that follow, as well as all possible modifications and variations derived from their equivalent concepts, should be construed as encompassing the scope of the present invention.

[0238] Although the present invention has been described with reference to the drawings exemplified above, it is to be understood that the present invention is not limited to the embodiments and drawings disclosed herein, and that various modifications may be made by those skilled in the art within the scope of the technical idea of ​​the present invention. Furthermore, even if the operational effects according to the configuration of the present invention have not been explicitly described while describing the embodiments of the present invention, it is natural that the effects predictable by the corresponding configuration should also be acknowledged.

Claims

1. A first die block having a first storage portion for accommodating a first coating material and extending along a first direction; A second die block extending along the first direction to correspond to the first die block and covering the first storage portion from the top to seal it from the outside; A shim plate disposed between the first die block and the second die block and providing a first slot through which the first coating material flows along a second direction perpendicular to the first direction; and A deformation suppressor arranged along the first direction so as to be spaced apart from the first storage portion along the second direction and to cross the first slot to prevent deformation of the shim plate. A die coater, including:

2. In claim 1, the shim plate, A base plate coupled to the first die block and the second die block along a third direction perpendicular to the first direction and the second direction and extending along the first direction; and Including two or more coating guides extending from the base plate in the second direction and spaced apart from each other so as to have a gap corresponding to the width of the first slot in the first direction, thereby defining the first slot; A die coater wherein the deformation suppressor and the coating guide are in contact with the second die block simultaneously.

3. In claim 2, A die coater, wherein the deformation suppressor comprises at least one connecting rod having a pair of adjacent coating guides and both ends connected thereto and extending along the first direction.

4. In claim 3, A die coater, wherein the above connecting rod is provided in a three-dimensional shape having a rod upper surface positioned at the same level as the guide upper surface, which is the upper surface of the coating guide, and a rod lower surface spaced apart from the rod upper surface by the load thickness in the third direction.

5. In claim 4, A die coater wherein the above load surface is formed as a flat surface parallel to the upper surface of the load at least in part, and the thickness of the load at least in part of the connecting rod is uniform along the second direction.

6. In claim 5, A die coater, wherein the connecting rod cut along the third direction has one of a square cross-section and a trapezoidal cross-section.

7. In claim 4, A die coater wherein the above-mentioned load is formed as a curved surface having a constant curvature at least in a portion thereof, and the load thickness is variable along the second direction.

8. In claim 7, A die coater, wherein the connecting rod cut along the third direction has one of a semicircular cross-section and an arc cross-section.

9. In claim 4, A die coater having a protruding portion in which the above-mentioned loading portion and the iron portion are alternately aligned along the first direction.

10. In claim 2, The above deformation suppressor has a connecting cross having a pair of inclined rods that are connected to each other at an angle to the adjacent coating guides and are positioned to intersect within the first slot. A die coater, including:

11. In claim 2, The above deformation suppressor is a connecting curve connected to the adjacent coating guide in a curved shape and having at least one bend within the first slot. A die coater, including:

12. In claim 2, A die coater, wherein the coating guides are arranged at regular intervals along the first direction, and a plurality of slots spaced apart by the width of the coating guides are aligned along the first direction.

13. In claim 2, A second storage unit extending from an input terminal recessed from the upper surface of the shim plate and positioned on the base plate to a plurality of output terminals (OUT) each positioned on a plurality of the coating guides and storing a second coating material; and A coupling protrusion that continuously protrudes from the lower surface of the second die block to correspond to the second storage portion and is coupled to the second storage portion to provide the second storage portion with a second slot for supplying the second coating material along the second direction. A die coater, including:

14. In claim 13, A die coater, wherein the second storage portion includes a defect groove that is joined by a fitting with the joining projection.

15. In claim 13, A die coater, wherein the first coating material comprises an active material slurry for a secondary battery, and the second coating material comprises an insulating material.

16. In claim 1, A die coater, wherein the distance from the edge of the first storage unit to the deformation suppressor is 1 to 1.5 times the distance from the spray tip through which the first coating material is sprayed to the deformation suppressor.

17. Storage tank for storing coating material; A supply module for supplying the coating material from the storage tank; A die coater is connected to the supply module and coats the coating material on a moving substrate, The above die coater, A first die block having a first storage unit for receiving the coating material and communicating with the supply module and extending along a first direction; A second die block extending along the first direction to correspond to the first die block and covering the first storage portion from the top to seal it from the outside; A shim plate disposed between the first die block and the second die block and providing a slot through which the coating material flows along a second direction perpendicular to the first direction; and A deformation suppressor arranged along the first direction so as to be spaced apart from the first storage portion along the second direction and to cross the slot to prevent deformation of the shim plate. A coating device having a .

18. In claim 17, the shim plate, A base plate coupled to the first die block and the second die block along a third direction perpendicular to the first direction and the second direction and extending along the first direction; and comprising two or more coating guides extending from the base plate in the second direction and spaced apart from each other to have a spacing corresponding to the width of the slot in the first direction, thereby defining the slot; A coating device wherein the deformation suppressor and the coating guide are in contact with the second die block simultaneously.

19. In claim 18, A coating device, wherein the deformation suppressor comprises at least one connecting rod having a pair of adjacent coating guides and both ends connected thereto and extending along the first direction.

20. In claim 18, The above deformation suppressor has a connecting cross having a pair of inclined rods that are connected to each other at an angle to the adjacent coating guides and are positioned to intersect within the slot. A coating device comprising:

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