Electrode Coating Die With Dam Layer for Stable Slurry Edges
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Solution Overview
Problem
The challenge is to adjust the amount of active material coated on electrodes to ensure safety in secondary battery manufacturing, as imbalances can lead to issues like explosion due to reduced mass of active material on the negative electrode.
Innovation Solution
An electrode coating die and apparatus that includes a slurry discharge part and a dam liquid discharge part to form a dam layer covering the edge portion of the active material slurry layer, maintaining the mass ratio of active materials on the electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the amount of active material coated on electrodes is not controlled, then the manufacturing process is simple, but the safety of the secondary battery cannot be guaranteed
Solution Approach 1:
A dam liquid is introduced as an intermediary substance between the active material slurry and the air environment. This dam liquid forms a dam layer that prevents the slurry from forming an inclined surface, thereby controlling the coating amount without requiring complex measurement and adjustment systems. The dam liquid acts as a mediator that naturally limits the spread of slurry through capillary action and surface tension.
Solution Approach 2:
The system utilizes the inherent properties of the dam liquid (viscosity, surface tension, capillary action) to automatically control the coating amount of active material. The dam layer self-regulates the slurry distribution without requiring external control mechanisms, making the process self-controlling and eliminating the need for complex monitoring and adjustment devices.
2Manufacturing precision
If a dam layer is formed to control active material coating amount, then the mass ratio of active materials is maintained, but the device structure becomes more complex
Solution Approach 1:
The coating die is segmented into distinct functional regions: a slurry discharge part for dispensing active material slurry and a dam liquid discharge part for dispensing dam liquid. This segmentation allows each part to perform its specific function independently, simplifying the overall design while achieving precise control over coating amounts through the coordinated action of these separate components.
Solution Approach 2:
The dam liquid discharge part is designed to discharge dam liquid that serves multiple functions: forming the dam layer to control slurry spread, preventing inclined surface formation, and maintaining the mass ratio of active materials. This multi-functional design eliminates the need for separate control mechanisms, reducing device complexity while achieving precise manufacturing control.
3Ease of manufacture
If the active material layer has an inclined surface, then the coating process is simple, but sliding sections form causing safety issues
Solution Approach 1:
The dam liquid is discharged simultaneously with or before the slurry to pre-form a dam layer that counteracts the natural tendency of slurry to form an inclined surface. This preliminary anti-action prevents the formation of sliding sections by creating a vertical wall effect at the edges of the active material layer, thereby eliminating safety issues before they can occur during electrode assembly.
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
This solution minimizes the formation of sliding sections, ensuring stable electrode assembly and preventing safety issues, allowing for increased battery size and energy density while reducing costs.
Implementation Method 1
a dam liquid discharge part provided on at least one side of the slurry discharge part and configured to discharge a dam liquid to form a dam layer covering at least a portion of an inclined surface portion
Implementation Method 2
form a dam layer covering at least a portion of an inclined surface portion provided at an edge portion of an active material slurry layer
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3
AI summary
The present invention provides an electrode coating die, including: a slurry discharge part configured to discharge an active material slurry onto a current collector; and a dam liquid discharge part provided on at least one side of the slurry discharge part and configured to discharge a dam liquid to form a dam layer covering at least a portion of an inclined surface portion provided at an edge portion of an active material slurry layer coated with an active material slurry discharged from the slurry discharge part, and an electrode coating apparatus including the same. Further, the present invention provides a method of manufacturing an electrode, the method including: a preparing operation of preparing an active material slurry including an active material, a conductive material, and a solvent; and a coating operation of applying the active material slurry on a current collector, in which the coating operation includes forming an active material layer by discharging the active material slurry onto the current collector and discharging a dam liquid so as to form a dam layer covering at least a portion of an inclined surface portion provided on an edge portion of at least one side of an active material slurry layer coated on the current collector at the same time.