Coating Die Gap Regulation for Stable Battery Slurry Flow
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Solution Overview
Problem
The flow of slurry extruded by conventional coating apparatuses is prone to fluctuations due to environmental factors affecting pressure sensors, leading to inconsistent thickness of the active substance layer on battery electrodes.
Innovation Solution
A coating die with a flow regulation member that moves along a direction intersecting with the longitudinal extension of the coating gap, regulated by a drive mechanism, allowing for precise control of the coating gap opening and slurry flow, unaffected by environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional coating die is used, then the coating process can be performed, but the slurry flow is prone to fluctuations due to environmental factors affecting pressure sensors
Solution Approach 1:
The patent replaces the pressure sensor-based flow control system with a mechanical regulation system. The flow regulation member directly mechanically adjusts the coating gap opening degree based on coating weight information, eliminating the need for pressure sensors that are susceptible to environmental interference. This mechanical substitution resolves the contradiction by removing the vulnerable sensing component while maintaining coating control capability.
Solution Approach 2:
The flow regulation member acts as an intermediary between the coating gap and the slurry flow. By positioning this regulation member at the coating gap to directly control the opening degree, it mediates the relationship between the die body and slurry flow, providing stable flow control that is not affected by environmental factors that would otherwise interfere with remote pressure sensing.
2Manufacturing precision
If the flow regulation member moves along a direction intersecting with the longitudinal extension of the coating gap, then precise control of coating gap opening is achieved, but the device complexity increases due to the drive mechanism
Solution Approach 1:
The patent introduces a new dimension of control by having the flow regulation member move along a second direction that intersects with the first direction (longitudinal extension of coating gap). This dimensional change allows the regulation member to effectively control the coating gap opening degree by moving perpendicular to or at an angle to the gap's length, providing precise control while maintaining a relatively simple drive mechanism structure.
Solution Approach 2:
The flow regulation member is designed to be movable along the second direction through the die body, transforming a static coating gap into a dynamically adjustable one. This dynamic capability allows real-time adjustment of the coating gap opening degree based on coating weight information, achieving high manufacturing precision without requiring overly complex mechanical structures.
3Manufacturing precision
If the flow regulation member extends into the coating gap, then the slurry flow can be precisely regulated, but the device complexity increases
Solution Approach 1:
The flow regulation function is extracted as a separate, movable regulation member that can be independently controlled. By taking out the flow control function from the fixed die structure and implementing it through a separate regulation member that moves along the second direction, the system achieves precise slurry flow regulation while keeping the overall device structure relatively simple and modular.
4Manufacturing precision
If closed-loop control is implemented using coating weight information, then coating consistency is improved, but the device complexity increases
Solution Approach 1:
The patent implements closed-loop control by using coating weight information as feedback to adjust the flow regulation member's position. The coating weight information is obtained in real-time and used to dynamically adjust the coating gap opening degree through the flow regulation member, ensuring consistent coating quality. This feedback mechanism achieves high coating precision without requiring overly complex control systems.
Data Source
AI summary
A coating die includes a die body and a regulation assembly. An accommodating cavity for accommodating a slurry is provided in the die body, and the die body is further provided with a coating gap communicating with the accommodating cavity and extending along a first direction. The regulation assembly includes a flow regulation member running through the die body along a second direction and capable of running into the coating gap. The regulation assembly further includes a drive mechanism, where the drive mechanism is connected to an end of the flow regulation member extending out of the die body so as to drive the flow regulation member to move along the second direction, and the drive mechanism is configured to be able to regulate displacement of the flow regulation member in the second direction according to coating weight information of a slurry flowing out of the coating gap.