Dual Slot Die Coater Assembly for Precise Die Lip Alignment
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Solution Overview
Problem
Existing slot die coaters face challenges in aligning die lips accurately and efficiently, leading to non-uniform coating of active material slurries on current collectors, which affects the quality and productivity of secondary battery electrodes.
Innovation Solution
A dual slot die coater design with integrated die blocks and shims that maintain contact with the base, allowing for easy alignment of die lips without the need for bolt adjustments, ensuring uniform coating gaps and reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If die blocks are assembled using blocks or spacers for die lip alignment, then die lip alignment can be achieved, but the process becomes complex with multiple matching conditions and low reproducibility
Solution Approach 1:
The die block is divided into a body portion and a die lip portion that can be independently adjusted. The die lip portion is segmented from the body portion, allowing separate positioning and alignment adjustments without affecting the entire die block assembly.
Solution Approach 2:
The die lip portion is made adjustable relative to the body portion through a positioning mechanism. This dynamic adjustment capability allows the die lip position to be optimized for alignment while maintaining the structural integrity of the die block.
2Manufacturing precision
If die lip alignment is adjusted using bolts, then alignment can be achieved, but the process takes time and greatly relies on operator skills
Solution Approach 1:
The die lip portion is pre-positioned with reference features on the body portion that guide its initial placement. This preliminary positioning reduces the adjustment time and minimizes reliance on operator skills during the alignment process.
Solution Approach 2:
A positioning mechanism acts as an intermediary between the die lip portion and the body portion, providing precise alignment through mechanical guidance features rather than direct bolt adjustment.
3Adaptability or versatility
If three die blocks are used to form two slots in a dual slot die coater, then dual coating capability is achieved, but die lip alignment becomes more difficult due to multiple contact surfaces
Solution Approach 1:
Each die block is segmented into body and die lip portions, with the die lip portion being the adjustable element. This segmentation allows independent alignment adjustment of each die lip regardless of the number of die blocks used.
Solution Approach 2:
The positioning mechanism and adjustable die lip design provide a universal alignment solution that works consistently across multiple die blocks, making the alignment process scalable from single-slot to multi-slot configurations.
Data Source
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AI summary
There is provided a dual slot die coater that is easy to align die lips. The dual slot die coater of the present disclosure includes a first slot and a second slot to deliver a coating solution in an opposite direction of gravity, and includes a first die block vertically installed and integrally formed with a base at a rear of an upper surface of the base; a second die block positioned in contact with the base in front of 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 in front of the second die block to form the second slot between the third die block and the second die block.