Modular Die Coater Lip Block for Flexible Electrode Patterning
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Solution Overview
Problem
Conventional die coaters are limited to producing electrodes of a single pattern, requiring a new manufacturing process when the insulating liquid coating position changes, leading to increased inconvenience and cost.
Innovation Solution
A die coater design that allows for simultaneous coating of two different liquids on an electrode base material, featuring a detachable lip block with adjustable insulating liquid flow paths and a shim assembly with body and sub shims to accommodate changes in coating position without full re-manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the position of the second slit is changed to adapt to different coating patterns, then the coating versatility is improved, but the device complexity increases as a new die coater must be manufactured
Solution Approach 1:
The die coater is divided into modular components: a fixed first block containing the insulating liquid inlet and first insulating liquid flow path, and a replaceable lip block containing the second insulating liquid flow path and second slit. By segmenting the device into interchangeable parts, different coating patterns can be achieved by simply replacing the lip block rather than redesigning the entire die coater structure.
Solution Approach 2:
The first block is designed as a universal component that can work with multiple types of lip blocks. The fixed insulating liquid inlet and first flow path serve multiple coating configurations, while different lip blocks provide specialized flow paths for various coating patterns. This multi-functionality allows a single base unit to adapt to different coating requirements.
2Ease of manufacture
If the insulating liquid flow path is fixed, then the manufacturing cost is reduced, but the coating position flexibility is worsened
Solution Approach 1:
The system transitions from a completely fixed flow path to a semi-dynamic configuration where the first flow path remains fixed for manufacturing simplicity, but the second flow path in the lip block can be changed by replacing components. This dynamic approach allows flexibility in coating position while maintaining ease of manufacture for the fixed portions.
Solution Approach 2:
The lip block is designed as a replaceable, relatively simple component compared to the entire die coater. When coating pattern changes are needed, only the lip block needs to be replaced rather than manufacturing a new complete die coater. This reduces the effective cost and complexity of adapting to different coating requirements.
Data Source
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AI summary
A die coater (10) includes a first block (100) having an insulating liquid inlet (120) and a second block (200) placed on the first block (100); and a shim assembly (300) interposed between the first block (100) and the second block (200) and configured to form a first slit (318) and a second slit (328, 428, 528) separated from each other; wherein the first block (100) comprises: a fixing portion (140) having a fixing flow path (121) therein that is a transfer path for an insulating liquid flowing in through the insulating liquid inlet (120); and a lip block (150) configured to be coupled to and detachable from the fixing portion (140) and forming a front end of the first block (100), wherein the lip block (150) has an insulating liquid flow (151, 152) path that is connected to the fixing flow path (121) and is a transfer path for the insulating liquid flowing in from the fixing flow path (121) to be discharged through the second slit (328, 428, 528).