Insulating Liquid Coating Die With Tilted Discharge to Prevent Bubbles
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Solution Overview
Problem
Conventional insulating liquid coating processes face challenges in preventing bubble formation due to empty spaces generated during the coating of high-viscosity insulating liquids on electrode active material layers, which can lead to defects and reduced coating efficiency.
Innovation Solution
A die for coating insulating liquids is designed with a discharge portion tilted at a predetermined angle, forming a bead-shaped discharge tip that minimizes empty spaces and prevents air inflow, ensuring continuous and efficient coating by adjusting the tilt angle, width, and length of the discharge portions to maintain a stable coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the insulating liquid is discharged vertically from the discharge portion, then the coating process is simple, but empty spaces are generated and bubbles form due to the high viscosity of the insulating liquid
Solution Approach 1:
The discharge portion is designed with an asymmetric tilt angle (5-45 degrees) relative to the vertical direction, creating an asymmetric discharge pattern that prevents air entrapment. This asymmetric configuration allows the insulating liquid to flow smoothly along the current collector surface without generating empty spaces, thereby eliminating bubble formation while maintaining coating simplicity.
Solution Approach 2:
The discharge direction is changed from a single vertical dimension to a two-dimensional angled discharge. By tilting the discharge portion at a specific angle, the insulating liquid is discharged in an direction that combines vertical flow with horizontal spreading, ensuring continuous contact with the current collector and preventing air pocket formation.
2Productivity
If the coating speed is increased to improve productivity, then the production efficiency increases, but the insulating liquid cannot properly fill the empty spaces, leading to coating defects
Solution Approach 1:
The tilted discharge portion pre-configures the insulating liquid flow path before discharge, creating a flow pattern that naturally fills empty spaces as the liquid exits. This preliminary configuration ensures that even at high coating speeds, the insulating liquid maintains continuous contact with the current collector and properly fills all gaps without requiring slower processing speeds.
3Reliability
If the viscosity of the insulating liquid is high to maintain insulation properties, then the insulation performance is improved, but the liquid stretches along the coating direction and generates empty spaces
Solution Approach 1:
The discharge angle parameter is optimized to a specific range (5-45 degrees) to counterbalance the effects of high viscosity. This parameter change modifies the discharge dynamics, allowing the viscous insulating liquid to spread appropriately along the current collector without excessive stretching or empty space formation, maintaining both insulation performance 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 solution effectively prevents bubble formation and ensures a stable, efficient coating process by forming a bead-shaped discharge tip, reducing the generation of empty spaces and maintaining a uniform coating thickness, thereby enhancing the quality and productivity of the insulating liquid coating.
Implementation Method 1
forming a bead-shaped discharge tip that minimizes empty spaces and prevents air inflow
Data Source
AI summary
A die for coating an insulating liquid may include a die body configured to be positioned on a current collector with a certain space and discharge an insulating liquid; and a discharge portion configured to be formed on one surface where the insulating liquid of the die body is discharged, and form a discharge path and a discharge port where the insulating liquid is discharged, wherein the discharge portion includes a first discharge portion positioned at a front region side of a coating direction of the insulating liquid, and a second discharge portion positioned at a rear region side of the coating direction of the insulating liquid, an insulating liquid discharge path is formed between the first discharge portion and the second discharge portion, and an insulating liquid discharge port is formed between an end of the first discharge portion and an end of the second discharge portion.