Dual Slot Die Coater Structure for Precise Die Lip Alignment
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Solution Overview
Problem
Conventional dual slot die coaters face challenges in aligning die lips accurately, leading to non-uniform coating and reduced reproducibility due to the complexity of die lip alignment and reliance on operator skills, which affects the thickness and uniformity of active material layers in secondary battery electrodes.
Innovation Solution
A dual slot die coater design featuring a first and second slot with die blocks in contact with a base, utilizing shims and a servomotor to maintain uniform die lip alignment and coating gap, eliminating the need for bolt adjustments and enhancing reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional dual slot die coater uses multiple die blocks with blocks or spacers for alignment, then die lip alignment can be achieved, but the alignment process becomes complex and relies on operator skills, reducing reproducibility
Solution Approach 1:
The patent removes the complex block or spacer alignment structures from the conventional die coater design. Instead, it uses a simple base with die blocks that directly contact the base surface, eliminating the need for additional alignment components and reducing structural complexity while maintaining alignment precision.
Solution Approach 2:
The die blocks are designed to self-align by contacting the base surface directly. The contact between the die blocks and the base provides automatic positioning without requiring external alignment mechanisms or operator intervention, thereby simplifying the structure and improving reproducibility.
2Manufacturing precision
If conventional dual slot die coater uses bolt adjustment for die lip alignment, then alignment can be achieved, but the process takes time and greatly relies on operator skills, resulting in low reproducibility
Solution Approach 1:
The die blocks are pre-designed with contact surfaces that naturally align with the base during assembly. This preliminary design eliminates the need for time-consuming bolt adjustments during operation, as the alignment is inherently built into the structure rather than requiring post-assembly adjustment.
Solution Approach 2:
The alignment function is built into the die block and base contact interface itself. The structure performs its own alignment function through geometric constraints and contact surfaces, eliminating the need for external adjustment mechanisms and operator skills, thereby reducing adjustment time and improving reproducibility.
3Adaptability or versatility
If dual slot die coater uses three die blocks for two slots, then dual slot coating capability is achieved, but forming each active material layer to desired thickness becomes difficult due to simultaneous exit from different ports
Solution Approach 1:
The patent applies different local characteristics to each die block and slot configuration to optimize coating thickness control. Each slot and its corresponding die block are designed with specific contact surface geometries and positions that are tailored to achieve uniform thickness for that particular coating operation, allowing dual slot capability while maintaining precision.
Data Source
AI summary
A dual slot die coater includes a first slot and a second slot to deliver a coating solution in an opposite direction of gravity. The dual slot die coater includes a first die block vertically installed and integrally formed with a base at a rear end of an upper surface of the base; a second die block positioned in contact with the base and alongside the first die block to form the first slot between the second die block and the first die block; and a third die block positioned in contact with the base alongside the second die block to form the second slot between the third die block and the second die block. The disclosed dual slot die coater allows for easy alignment of the die lips.