Dual-Slot Die Coater Assembly for Widthwise Gap Uniformity
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Solution Overview
Problem
Conventional slot die coaters face challenges in maintaining uniform coating quality and controlling the width-direction deviation of the coating gap, especially when dealing with multiple active material slurries, leading to non-uniform electrode manufacturing and increased production time.
Innovation Solution
A dual-slot die coater design featuring a first and second slot with an alignment block that securely fastens die blocks together, ensuring a consistent coating gap through precise alignment and bolting, allowing for simultaneous coating of two types of active material slurries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional slot die coater uses multiple die blocks to form multiple slots for simultaneous coating of different active material slurries, then productivity is improved by coating multiple layers simultaneously, but manufacturing precision deteriorates due to difficulty in controlling coating gap uniformity across multiple die blocks
Solution Approach 1:
The die assembly is divided into multiple independent die blocks (first die block, second die block, third die block) that can be separately manufactured and precisely positioned. Each die block forms a separate slot, allowing independent control of coating parameters while maintaining overall system precision through the alignment block structure.
Solution Approach 2:
An alignment block is introduced as an intermediary component between the die blocks and the base. This alignment block includes positioning structures that mediate the spatial relationships between multiple die blocks, ensuring uniform coating gaps across all slots while maintaining the productivity benefits of simultaneous multi-layer coating.
2Productivity
If the width of the dual-slot die coater is increased to accommodate long-width current collectors for higher production, then productivity is improved, but manufacturing precision deteriorates due to increased difficulty in maintaining uniform coating gap across the width direction
Solution Approach 1:
The die assembly is segmented into multiple die blocks arranged in the width direction, allowing the coater to handle wide current collectors while maintaining precise control over coating gap uniformity across the entire width through individual positioning of each die block relative to the alignment block.
Solution Approach 2:
The alignment block serves as a mediator that distributes and maintains uniform coating gaps across the entire width of the coater. By positioning multiple die blocks relative to this central alignment reference, the system achieves width-direction uniformity even as the overall coater width increases to accommodate larger current collectors.
3Productivity
If die blocks are closely spaced to form multiple slots for simultaneous coating, then productivity is improved by coating multiple active material layers at once, but reliability deteriorates due to difficulty in maintaining stable coating gap under discharge pressure
Solution Approach 1:
The alignment block pre-establishes the correct spacing and positioning between die blocks before the coating process begins. This preliminary alignment ensures that coating gaps are uniformly set and maintained, preventing deformation or misalignment even when die blocks are closely spaced for high-productivity multi-layer coating operations.
Solution Approach 2:
The alignment block acts as a mechanical intermediary that stabilizes the spacing between closely-spaced die blocks. It provides a rigid reference structure that maintains uniform coating gaps under discharge pressure, enabling reliable simultaneous coating of multiple active material layers without gap variation.
Data Source
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AI summary
A dual-slot die coater capable of easy coating gap adjustment and control of a width direction deviation of a coating gap is provided. The dual-slot die coater includes a first slot and a second slot for discharging a coating solution in a direction opposite to gravity. The dual-slot die coater includes a first die block vertically installed on a rear portion of an upper surface of a base, a second die block arranged on a front surface 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 arranged on a front surface of the second die block to form the second slot between the third die block and the second die block, and further includes an alignment block provided between a front portion of the upper surface of the base and a lower surface of the second die block and fastened and coupled to the lower surface of the second die block and a lower surface of the first die block by bolts.