Coating Die Head Regulators for Edge Bulging Control
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Solution Overview
Problem
In battery production, achieving precise thickness adjustment of the coating layer is challenging due to edge bulging issues, where the edge regions often have thicker coatings than the middle regions, affecting battery performance.
Innovation Solution
A coating die head with regulators of varying lengths and numbers in different regions allows for precise thickness adjustment by differing regulators in the main and edge regions, ensuring consistent and uniform coating thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single uniform regulator is used for the entire discharge channel, then the device complexity is low, but the manufacturing precision of coating thickness cannot be achieved in different regions
Solution Approach 1:
The discharge channel is divided into multiple regions (main coating region and edge region), and each region is equipped with regulators of different lengths. This segmentation allows independent thickness control for each region, resolving the contradiction between uniform device structure and region-specific precision requirements.
Solution Approach 2:
Regulators with different lengths are assigned to different regions based on their specific coating requirements. The main coating region uses longer regulators while edge regions use shorter regulators, creating local quality variations that enable precise thickness control in each zone without requiring complete device redesign.
2Manufacturing precision
If regulators of different lengths are used in different regions, then the manufacturing precision of coating thickness is improved, but the ease of manufacture decreases
Solution Approach 1:
Instead of manufacturing completely different regulator types, the solution uses regulators of the same basic design but with locally varied lengths. This approach maintains manufacturing simplicity while achieving the required precision through dimensional variation rather than structural complexity.
Data Source
AI summary
A coating die head includes a die head body and at least two regulators. A discharge channel communicating with an external environment is disposed on the die head body. The discharge channel includes a discharge port. The discharge port extends along a first direction. The first direction intersects a discharge direction of the discharge channel. The at least two regulators are disposed on the die head body and distributed along the first direction. At least a part of each regulator is movable in the discharge channel along a second direction. The second direction is perpendicular to the discharge direction and the first direction. A dimension along the first direction differs between the at least two regulators.