Multi-Slot Die Coater Assembly for Uniform Wide-Web Coating
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Solution Overview
Problem
Conventional multi-slot die coaters are prone to deformation and twist due to their structural vulnerability, leading to non-uniform coating and difficulties in maintaining the desired thickness of electrode active material layers, especially when coating wide current collectors for high-energy density secondary batteries.
Innovation Solution
A multi-slot die coater design featuring inclined contact surfaces between die blocks with bolts fastened perpendicular to these surfaces, reducing the risk of slip and maintaining consistent coating gaps, thereby minimizing deformation and ensuring uniform coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multi-slot die coater uses thin die blocks to reduce device size, then device footprint is reduced, but structural vulnerability to deformation and twist increases
Solution Approach 1:
The patent introduces an inclined contact surface between die blocks, transforming the fastening geometry from a conventional vertical arrangement to a tilted configuration. This dimensional change in the fastening approach allows bolts to engage at an angle that simultaneously achieves secure connection and prevents deformation, resolving the contradiction between compact size and structural strength.
Solution Approach 2:
The patent employs asymmetric fastening by tilting the contact surface between die blocks at a specific angle (e.g., 15-45 degrees) rather than using a symmetric vertical arrangement. This asymmetry in the fastening geometry creates optimal stress distribution that prevents both deformation and twist, allowing thin die blocks to maintain sufficient structural rigidity while keeping the device footprint small.
2Ease of manufacture
If conventional vertical bolt fastening is used, then assembly is simple, but slip occurs during fastening causing deformation
Solution Approach 1:
The patent changes the fastening approach from a vertical (one-dimensional) arrangement to an inclined (angular) configuration. By tilting the contact surface between die blocks, the bolt fastening occurs along an angled path that eliminates slip during assembly while maintaining manufacturing simplicity. This dimensional change in fastening geometry prevents deformation and ensures uniform coating gaps.
Solution Approach 2:
The inclined contact surface creates a angular geometry that optimizes the fastening process. The tilted arrangement of the contact surface between die blocks allows bolts to engage in a manner that distributes stress evenly, preventing slip and deformation while maintaining assembly simplicity.
3Manufacturing precision
If die blocks are tilted to prevent slip, then coating uniformity improves, but bolt fastening becomes more complex
Solution Approach 1:
The patent introduces an inclined contact surface between die blocks, transforming the fastening geometry from a conventional vertical arrangement to a tilted configuration. This dimensional change in the fastening approach allows bolts to engage at an angle that simultaneously achieves secure connection and prevents deformation, resolving the contradiction between compact size and structural strength.
Solution Approach 2:
The patent applies the inclined contact surface specifically at the interface between die blocks where fastening occurs, rather than tilting the entire die coater structure. This localized application of the倾斜 geometry maintains overall structural simplicity while achieving the desired prevention of slip and deformation at the critical fastening points.
Data Source
AI summary
A multi-slot die coater includes a first slot and a second slot to extrude and coat a coating solution on a surface of a continuously moving substrate through at least one of the first slot or the second slot, and includes a first outer die block; an intermediate die block positioned on the first outer die block such that the first slot is formed between the intermediate die block and the first outer die block; and a second outer die block positioned on the intermediate die block such that the second slot is formed between the second outer die block and the intermediate die block, wherein the die-coater includes contact surfaces between the first outer die block, the intermediate die block and the second die block that are inclined relative to a first plane and a fastener is fastened substantially perpendicular to one of the inclined contact surfaces.