Double-Layer Electrode Slurry Coating Without Layer Mixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for forming a double-layer active material structure on electrodes in secondary batteries are inefficient, as the lower and upper active material layers often mix during the slurry coating process, preventing the desired double-layer structure from being achieved.
Innovation Solution
An electrode slurry coating apparatus with a specific configuration, including a first and second discharge port and a movement controller, ensures that the lower and upper slurry layers are formed without mixing by controlling the distance and timing of the coating apparatus movement relative to the current collector, allowing for precise formation of the double-layer structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If slurry for lower and upper active material layers is discharged simultaneously, then coating process is simplified, but lower and upper active materials mix and desired double-layer structure cannot be formed
Solution Approach 1:
The coating apparatus is divided into multiple discharge ports (first discharge port for lower layer, second discharge port for upper layer) positioned at different locations. This segmentation allows independent control of slurry discharge for each layer, preventing mixing while maintaining process efficiency.
Solution Approach 2:
The first discharge port discharges slurry to form the lower layer before the second discharge port discharges slurry for the upper layer. This preliminary action sequence ensures that the lower layer is already in place and can support the upper layer, preventing mixing while maintaining structural integrity.
2Manufacturing precision
If coating apparatus moves in opposite direction to discharge direction, then upper slurry layer can be formed on lower slurry layer without mixing, but process complexity increases
Solution Approach 1:
The coating apparatus incorporates a movement controller that dynamically adjusts the position of the apparatus in the opposite direction to the discharge direction. This dynamic movement allows precise control of slurry deposition location, enabling formation of the upper layer on the lower layer without mixing, while the automation reduces operational complexity.
Solution Approach 2:
The movement controller uses feedback mechanisms to monitor and adjust the position of the coating apparatus during the coating process. This feedback control ensures that the apparatus moves the correct distance in the opposite direction, maintaining precision in double-layer formation while simplifying operator intervention.
3Area of stationary object
If distance H1 is less than 60% of upper slurry layer thickness, then coating area is sufficient, but slurry leaks back and cannot be coated properly
Solution Approach 1:
The system optimizes the distance parameter H1 between the discharge port and the current collector to be within 60-140% of the upper slurry layer thickness. This parameter adjustment ensures that the coating area is sufficient to accommodate the slurry volume while preventing leakage and maintaining proper coating quality.
Data Source
AI summary
The present invention relates to electrode slurry coating apparatus and method, the present invention ultimately allowing the process efficiency to be increased and rate of errors to be reduced when double-layer structured active material layers are formed by temporally adjusting the height of first and second discharge outlets through which active material is discharged.