Flow Guide Geometry for Sharp Electrode Thickness Profiles
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Solution Overview
Problem
Conventional systems are unable to deposit materials on a substrate with a specific thickness profile, particularly with sharp transitions between distinct thickness levels, and lack precision and efficiency in achieving desired thickness profiles for battery manufacturing.
Innovation Solution
A system comprising a die with a flow guide that includes a flow narrowing portion and a flow shaping portion, which blocks the material from flowing in the principal deposition direction and shapes the flow to achieve a precise thickness profile by redirecting and aligning the material, allowing for a more pronounced and defined thickness profile with steep transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional deposition systems are used, then the material can be deposited on the substrate, but the thickness profile cannot be precisely controlled with sharp transitions between distinct thickness levels
Solution Approach 1:
The flow guide is divided into multiple functional segments: a flow narrowing portion with a narrowed width and a flow shaping portion with a wider width. This segmentation allows independent control of different flow characteristics, enabling precise thickness profiling with sharp transitions by restricting flow in the narrowing portion while shaping the overall flow pattern in the shaping portion.
Solution Approach 2:
Different portions of the flow guide are designed with locally optimized geometries. The flow narrowing portion has a reduced width to create a specific flow restriction zone, while the flow shaping portion has a larger width to establish the desired flow distribution pattern. This local quality variation enables precise control over the thickness profile at different locations on the substrate.
2Manufacturing precision
If the flow guide restricts material flow to achieve sharp thickness transitions, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The flow guide combines multiple functions into a single integrated component. Both the flow narrowing function (to restrict material flow and create sharp transitions) and the flow shaping function (to establish the overall thickness profile) are merged into one flow guide structure, eliminating the need for separate components and simplifying the overall device architecture.
Solution Approach 2:
The flow guide serves multiple purposes simultaneously: it narrows the flow to create sharp thickness transitions, shapes the overall flow distribution pattern, and controls the deposition uniformity across the substrate. This multi-functionality reduces the number of separate components needed and simplifies the device while achieving precise thickness profiling.
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 system enables precise control of the thickness profile of the deposited material, facilitating accurate configuration of secondary batteries with improved material usage and energy density by achieving sharp transitions and uniform central regions.
Implementation Method 1
The die is configured to extrude the material in a principal deposition direction through the opening
Implementation Method 2
The flow guide is configured to shape a flow of the material extruded by the die
Data Source
AI summary
A system for depositing a material includes a die and a flow guide. The die includes an opening and a cavity communicating with the opening. The die is configured to extrude the material in a principal deposition direction through the opening. The flow guide is disposed in the cavity and is configured to shape a flow of the material extruded by the die. The flow guide includes a flow narrowing portion and a flow shaping portion. The flow narrowing portion extends in a width direction perpendicular to the principal deposition direction so as to block the material from flowing through in the principal deposition direction. The flow shaping portion extends downstream from the flow narrowing portion in the principal deposition direction. A width of the flow shaping portion is smaller than, or decreases from, a width of the flow narrowing portion.