Electrode Slurry Flow Conditioning for Uniform Slot-Die Coating
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Solution Overview
Problem
Existing methods for coating electrode slurry on current collectors face challenges in uniformly applying the material due to high pressure at the central portion, leading to non-uniform velocity distribution and deviation in the coating process.
Innovation Solution
An electrode coating apparatus and method that incorporates a turbulent flow generator with a mesh or honeycomb structure in the flow path to generate a turbulent flow, ensuring uniform velocity distribution of the electrode slurry before application onto the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrode slurry is supplied to the die coater through a conventional flow path, then the coating process can be performed, but high pressure at the central portion causes non-uniform velocity distribution and poor coating uniformity
Solution Approach 1:
The flow path cross-section is segmented into multiple flow channels by partition walls, dividing the single large flow path into several smaller parallel flow paths. This segmentation distributes the electrode slurry flow more evenly across the cross-section, preventing excessive pressure concentration at the central portion and improving velocity distribution uniformity, thereby enhancing coating uniformity.
Solution Approach 2:
The flow path structure is designed with different local characteristics - the partition walls create regions with optimized flow characteristics in different areas of the cross-section. This local structural modification ensures that each region of the flow path has appropriate flow resistance and velocity distribution, preventing the central portion from having excessively high pressure and velocity while maintaining adequate flow in other regions.
2Productivity
If electrode slurry is supplied at high pressure to maintain productivity, then coating speed is improved, but velocity deviation increases and coating uniformity deteriorates
Solution Approach 1:
By segmenting the flow path into multiple channels with partition walls, the total flow rate can be increased for higher productivity while each individual channel maintains manageable flow velocity. This prevents excessive velocity deviation that would occur in a single large flow path at high flow rates, thereby maintaining coating uniformity even at higher productivity levels.
Solution Approach 2:
The segmented flow path structure dynamically adapts to different flow rates - at higher total flow rates, each segment handles a proportional increase in flow, maintaining relatively uniform velocity distribution across segments. This dynamic balance allows productivity enhancement without sacrificing velocity distribution uniformity and coating quality.
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 apparatus and method effectively reduce velocity deviation and pressure drop, resulting in more uniform application of the electrode slurry across the substrate, enhancing coating consistency.
Implementation Method 1
a turbulent flow generator provided within the flow path and configured to generate a turbulent flow in the electrode slurry within the flow path
Data Source
Figure 1~2(b)
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AI summary
The present specification relates to an electrode coating apparatus and an electrode coating method that include a turbulent flow generator to uniformize a distribution of a velocity of a coating material transferred from a supply tank to an injection port of a slot die.