Multi-Cavity Slot Die for Uniform Battery Electrode Coating
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Solution Overview
Problem
Existing slot dies for manufacturing rechargeable battery electrodes suffer from variance in loading level across the width direction, leading to inconsistent cell capacity and performance.
Innovation Solution
The slot die design includes a first cavity and a second cavity connected through passages, which minimizes stagnation and ensures uniform flow speed of the active material slurry across the width direction, thereby reducing loading level variance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional slot die with a single cavity is used, then the device complexity is low, but the loading level uniformity across the width direction deteriorates due to slurry stagnation
Solution Approach 1:
The slot die is divided into multiple independent cavities (first cavity, second cavity, third cavity) connected by passage sections. Each cavity handles a specific width region of the substrate, allowing independent slurry flow control. This segmentation eliminates stagnation in single-cavity designs and ensures uniform loading level across the entire width direction.
Solution Approach 2:
The invention introduces a height dimension by stacking cavities vertically (first cavity at lower height, second cavity at intermediate height, third cavity at upper height). The passage sections connect cavities across different height levels, creating a three-dimensional slurry distribution network that improves flow uniformity while managing device complexity through vertical arrangement.
2Manufacturing precision
If the slot die structure is simplified, then the ease of manufacture is high, but the flow speed uniformity of slurry deteriorates leading to loading level variance
Solution Approach 1:
Each cavity is designed with specific local characteristics: the first cavity has a first cross-sectional area, the second cavity has a second cross-sectional area, and the third cavity has a third cross-sectional area. The passage sections are positioned at specific locations within each cavity to optimize local flow distribution. This local quality approach ensures uniform flow speed across different width regions while maintaining manufacturability through standardized cavity designs.
Solution Approach 2:
The invention varies the cross-sectional areas of different cavities and the positions of passage sections to optimize slurry flow distribution. By adjusting these geometric parameters, the design achieves uniform flow speed across the width direction without requiring overly complex manufacturing processes.
3Reliability
If a single cavity design is used, then the device complexity is low, but the slurry stagnation increases reducing coating quality
Solution Approach 1:
The slot die is divided into multiple independent cavities (first cavity, second cavity, third cavity) connected by passage sections. Each cavity handles a specific width region of the substrate, allowing independent slurry flow control. This segmentation eliminates stagnation in single-cavity designs and ensures uniform loading level across the entire width direction.
Solution Approach 2:
The passage sections ensure continuous slurry flow from one cavity to the next, preventing stagnation. The multi-cavity design maintains continuous action of slurry delivery across the entire substrate width, improving coating quality by ensuring fresh slurry reaches all regions without pooling or stagnation.
Data Source
AI summary
A slot die for manufacturing a rechargeable battery electrode according to an embodiment includes a first block; a second block disposed on the first block; a third block disposed opposite to the second block; and a shim member that is disposed between the second block and the third block and forms a slot outlet in a width direction and a height direction. The first block forms a first cavity that receives an active material slurry supplied between the first block and the second block and forms a connection passage between the first block and the second block in a width direction and the height direction of the slot outlet. The second block forms a second cavity that receives the active material slurry supplied through the connection passage and discharges the received active material slurry through the slot outlet.