Battery Coating Die with Protrusion for Thickness Profile Control
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Solution Overview
Problem
Existing manufacturing processes face challenges in achieving a precise thickness profile of deposited materials, particularly in areas extending along the principal deposition direction, which is crucial for battery manufacturing.
Innovation Solution
A system with a die that includes a protrusion portion extending through the cavity and opening, shaping the material flow to achieve a specific thickness profile by reducing thickness in specific positions, using a base portion and separation portions to control the material deposition accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a uniform material deposition is applied over the entire substrate, then the deposition process is simple and fast, but the thickness accuracy in specific areas (such as electrode tabs) deteriorates
Solution Approach 1:
The die structure incorporates a protrusion portion that creates a localized flow resistance in specific areas, allowing the material thickness to be precisely controlled in those regions while maintaining uniform deposition elsewhere. This local modification of the die geometry enables area-specific thickness control without complicating the overall deposition system.
Solution Approach 2:
The die is segmented into different functional regions: a base portion for general material flow, separation portions for controlling material distribution, and a protrusion portion for localized thickness reduction. This segmentation allows each region to perform its specific function independently, achieving precise thickness profiles through coordinated action of discrete structural elements.
2Manufacturing precision
If the material flow is not controlled in specific areas, then the deposition process is simple, but the thickness uniformity in areas extending along the principal deposition direction deteriorates
Solution Approach 1:
The protrusion portion is strategically positioned to create localized flow resistance only in areas requiring thickness reduction (such as electrode tab regions). This local intervention maintains simple uniform deposition in most areas while achieving precise thickness control where needed, minimizing overall device complexity.
Solution Approach 2:
The protrusion portion acts as an intermediary element between the material source and the substrate, mediating the material flow to achieve desired thickness profiles. By introducing this intermediate structural feature in the die, the system can control material distribution without requiring complex external flow control mechanisms.
3Manufacturing precision
If a protrusion portion is added to the die to control thickness, then the thickness profile accuracy improves, but the device complexity increases
Solution Approach 1:
Rather than redesigning the entire die structure, the invention adds a localized protrusion portion that creates flow resistance only where needed. This minimal structural addition achieves precise thickness control in specific areas while keeping the overall die structure simple and the deposition process efficient.
Solution Approach 2:
Instead of trying to increase material flow in areas requiring thickness reduction, the invention does the opposite by creating a protrusion that locally restricts flow. This inverted approach (restricting flow where needed rather than enhancing it) achieves the desired thickness profile with a simple structural modification.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables precise control of the thickness profile of the deposited material, allowing for uniform deposition with reduced thickness in desired areas, enhancing manufacturing accuracy and preventing undesirable crystallization.
Implementation Method 1
The die (10) is configured for extruding a material (M) along a principal deposition direction (D) through an opening (12) of the die (10)
Implementation Method 2
The protrusion portion (16) is configured for shaping a flow of the material (M) extruded from the die (10). The protrusion portion (16) extends through the cavity (14) and extends out of the opening (12). The die (10) is configured to deposit material (M) with a reduced thickness in a position on a substrate corresponding to a size and a position of the protrusion portion (16)
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
Disclosed is a system for depositing a material. The system comprises a die for extruding the material along a principal deposition direction through an opening of the die. The die comprises a cavity and a protrusion portion. The cavity is configured for receiving the material. The cavity is fluidly connected to the opening of the die. The protrusion portion is configured for shaping a flow of the material extruded from the die. The protrusion portion extends through the cavity and extending out of the opening.