Electrode Slurry Coating Head Sealing to Prevent Die Leakage
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Solution Overview
Problem
Conventional electrode producing coating apparatuses suffer from slurry leakage at the outer surfaces of the die and shim units, leading to coating defects, weak welding, and increased ignition risks due to uncontrolled electrode slurry distribution.
Innovation Solution
A coating apparatus with a cover member that surrounds the outer surfaces of the die and shim units, except for the outlet, to prevent slurry leakage, using a cover film with an adhesive layer and unwinder/winder system to ensure tight sealing and easy replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional coating apparatus without a cover member is used, then the structure is simple and easy to manufacture, but electrode slurry leaks at the outer surface of the die and shim units causing coating defects
Solution Approach 1:
The coating apparatus is divided into functional segments: the die unit for slurry discharge, the shim unit for gap formation, and the cover member for sealing. This segmentation allows each component to perform its specific function effectively while maintaining overall system simplicity.
Solution Approach 2:
The harmful slurry leakage phenomenon is extracted and isolated by introducing a cover member that specifically targets the leakage path. The cover member is positioned to seal only the outer surface gaps between the die and shim units, leaving the outlet functionality unchanged.
2Reliability
If no cover member is used, then the device structure remains simple, but slurry accumulates on uncoated portions leading to weak welding and ignition risks
Solution Approach 1:
The cover member is installed in advance to prevent slurry leakage before it can accumulate on uncoated portions. By sealing the gaps between the die and shim units, the cover member proactively stops the harmful effect of slurry migration, ensuring clean welding surfaces and reducing ignition risks.
Solution Approach 2:
The cover member acts as an intermediary element between the slurry discharge system and the environment. It mediates the slurry flow by allowing controlled discharge through the outlet while blocking unintended leakage paths, thus protecting the welding areas from slurry contamination.
3Manufacturing precision
If the die and shim units are perfectly aligned without gaps, then slurry leakage is prevented, but manufacturing tolerance makes perfect alignment difficult to achieve
Solution Approach 1:
The alignment tolerance issue is extracted and addressed separately by introducing a cover member that seals the gaps caused by misalignment. This allows the die and shim units to be manufactured and assembled with normal tolerances without compromising the sealing effectiveness.
Solution Approach 2:
The cover member provides localized sealing quality at the critical gap areas between the die and shim units. Rather than requiring perfect alignment throughout the entire assembly, the cover member ensures sealing precision only where slurry leakage is problematic, maintaining ease of manufacture for the main components.
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 solution effectively reduces coating defects by preventing slurry from coating unneeded areas, ensuring stronger electrode tab welding and reducing ignition risks by maintaining controlled slurry distribution.
Implementation Method 1
a cover member configured to surround an outer surface of the die unit and the shim unit so that the electrode slurry is not leaked at the outer surface, except for the outlet
Data Source
AI summary
Disclosed is a coating apparatus for producing an electrode, which has a reduced defect rate in the coating process. The coating apparatus includes a die unit having an inlet through which the electrode slurry is introduced and an inner space for accommodating the introduced electrode slurry; a shim unit mounted in the die unit and configured to form an outlet together with the die unit so that the electrode slurry is discharged therethrough; and a cover member configured to surround an outer surface of the die unit and the shim unit so that the electrode slurry is not leaked at the outer surface, except for the outlet.