Integrated Shim Coating Die for Precise Two-Layer Alignment
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Solution Overview
Problem
Existing coating dies require manual adjustment with micron-order accuracy to align the coating positions of two layers, which is time-consuming and degrades repeatability, especially in applications like lithium-ion cell manufacturing where precise alignment is critical.
Innovation Solution
A coating die design featuring an integrated shim with recesses on both faces, eliminating the need for separate upper and lower shims and reducing assembly steps, while improving positioning accuracy by defining discharge slots for two different coating liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate upper and lower shims are used with manual adjustment, then the coating die can be assembled, but the positioning accuracy and assembly time are degraded
Solution Approach 1:
The patent merges the upper shim and lower shim into a single integrated shim component. This integrated shim contains both the first recess (for upper layer coating liquid) and the second recess (for lower layer coating liquid), eliminating the need for separate shims and manual positioning adjustments. The merging resolves the contradiction by providing fixed, precise positioning without time-consuming assembly steps.
Solution Approach 2:
The integrated shim is designed with predetermined recess positions that automatically ensure accurate alignment between the two coating layers. The shim structure itself provides the positioning function without requiring external adjustment mechanisms or operator intervention, achieving self-service positioning that improves both accuracy and reduces assembly time.
2Manufacturing precision
If manual adjustment is performed with micron-order accuracy, then coating alignment is achieved, but the repeatability and productivity are degraded
Solution Approach 1:
By combining the positioning functions for both coating layers into a single integrated shim, the patent eliminates repetitive manual adjustment operations. The unified structure ensures consistent positioning accuracy across multiple assemblies, improving repeatability and productivity simultaneously.
Solution Approach 2:
The recesses in the integrated shim are pre-positioned during manufacturing with the exact spacing and alignment required for proper coating layer positioning. This preliminary action of pre-establishing precise geometry eliminates the need for time-consuming on-site adjustments, thereby improving both accuracy and assembly speed.
3Adaptability or versatility
If separate shims are used requiring positioning adjustment, then the coating die structure is flexible, but the positioning repeatability is degraded
Solution Approach 1:
The integration of both shim functions into one component standardizes the positioning mechanism. This merging maintains the necessary adaptability through the recess design while ensuring that the positioning relationship between upper and lower layers is fixed and repeatable, resolving the contradiction between flexibility and repeatability.
Data Source
AI summary
Provided is a coating die enabling coating of two layers of coating films stably. The coating die includes: a first block including a first manifold to receive a first coating liquid; a second block including a second manifold to receive a second coating liquid; and a shim sandwiched between the first block and the second block.