Adjustable Die Coater Assembly for Uniform Battery Electrode Coating
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Solution Overview
Problem
Die coater systems struggle to maintain consistent thickness, width, and density of active material layers on foils for battery electrodes, leading to subpar battery quality due to temperature control issues and uneven coating.
Innovation Solution
A die coater system with adjustable discharge ports and a mechanism to deform the die block assembly, allowing for precise control of the coating distance and layer thickness by urging sections of the die block assembly forward or backward, ensuring even and consistent coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the die block assembly is rigid and fixed in position, then the structural stability is maintained, but the coating distance cannot be adjusted, leading to inconsistent layer thickness and width
Solution Approach 1:
The die block assembly is divided into multiple sections that can be independently deformed. Each section can be adjusted separately to control the discharge port position, allowing precise control of coating parameters while maintaining overall structural integrity through modular segmentation.
Solution Approach 2:
The die block assembly transitions from a rigid fixed structure to a dynamically adjustable structure. The deformation mechanism allows the die block to change its configuration during operation, enabling real-time adjustment of coating distance and discharge port positioning to achieve consistent coating thickness and width.
2Manufacturing precision
If the discharge port position is fixed, then the device simplicity is maintained, but the active material layer thickness and width cannot be controlled, resulting in subpar coating quality
Solution Approach 1:
The discharge port position is made dynamically adjustable through the deformation of die block sections. This allows the coating distance to be modified during operation to achieve precise control over layer thickness and width, while the automated deformation mechanism maintains ease of operation.
Solution Approach 2:
The system controls coating parameters by changing the physical configuration of the die block assembly. By deforming the die block sections, the discharge port position and coating distance are adjusted, enabling precise control of active material layer thickness and width without complex manual adjustments.
3Manufacturing precision
If the die block assembly is deformed to adjust coating distance, then the coating evenness is improved, but the structural stability may be compromised
Solution Approach 1:
Segmenting the die block into deformable sections allows localized adjustments that improve coating evenness while maintaining overall structural stability. Each segment can be independently deformed to optimize coating parameters without compromising the integrity of the entire die block assembly.
Solution Approach 2:
The die block assembly employs controlled deformation rather than rigid fixation. This dynamic approach allows the structure to adapt its configuration for optimal coating evenness while the deformation mechanism is designed to maintain structural stability throughout the adjustment range.
Data Source
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AI summary
Die coater system configured for coating a foil with an active material, comprises a die block assembly with at least one discharge port for dispensing an active material slurry onto the foil, wherein the discharge port defines a discharge direction and extends in a lateral direction, wherein the die coater system further includes at least one adjustment device coupled to a back side of the die block assembly opposite to the discharge port, wherein the adjustment device includes an actor configured to urge at least a section of the die block assembly forwards or backwards in the discharge direction.