Dual Slot Die Coating for Uniform High-Loading Electrodes
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Solution Overview
Problem
Existing methods for manufacturing electrodes in secondary batteries face challenges in increasing the loading amount and uniformity of the electrode mixture layer, particularly in high-capacity batteries, and require efficient control of binder distribution to improve rapid charging performance and reduce detachment phenomena.
Innovation Solution
A dual slot die coater with temperature control mechanisms, including a temperature controller with coolant and heating wires, is used to maintain optimal supply pressure by adjusting the temperature of the coating material within the manifold, ensuring uniform coating and efficient binder distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large amount of electrode slurry is applied on the current collector during coating to increase the loading amount, then the capacity of secondary batteries is increased, but the coating uniformity deteriorates
Solution Approach 1:
The patent divides the coating process into two separate coating operations using two slot dies, each applying a different coating material. This segmentation allows independent control of each coating layer's thickness and composition, enabling high loading amounts while maintaining uniform coating quality for each layer.
Solution Approach 2:
The patent applies different coating materials with different properties to different locations or layers of the current collector. The first coating material contains binder for adhesion, while the second coating material has optimized composition for capacity. This local differentiation allows each layer to perform its specific function optimally, achieving both high loading and uniform coating.
2Reliability
If the temperature of the coating material is not controlled during coating, then the supply pressure becomes unstable, but temperature control mechanisms add device complexity
Solution Approach 1:
The patent actively controls the temperature parameter of the coating material during the coating process. By maintaining stable temperature, the viscosity and flow characteristics of the coating material remain consistent, which ensures stable supply pressure and uniform coating quality throughout the manufacturing process.
Solution Approach 2:
The patent implements temperature control mechanisms that monitor and adjust the temperature of the coating material in real-time. This feedback control ensures that temperature deviations are corrected immediately, maintaining stable supply pressure and coating quality without requiring overly complex manual intervention systems.
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 dual slot die coater stabilizes the coating process, enhances rapid charging performance, and improves the yield of electrodes by maintaining uniform thickness and reducing binder content, thereby improving the manufacturing efficiency and stability of the electrode mixture layer.
Implementation Method 1
a temperature controller provided in the first die block and capable of controlling temperature
Implementation Method 2
the temperature controller may include a flow path for a coolant
Implementation Method 3
the temperature controller may include a flow path for a coolant and a heating wire
Data Source
AI summary
Proposed is a dual slot die coater, which includes a first die block provided with a first manifold for accommodating the first coating material, a second die block provided on one side of the first die block, a third die block interposed between the first die block and the second die block, a second manifold provided in either the second die block or the third die block and accommodating a second coating material, and a temperature controller provided in the first die block and capable of controlling temperature.