Multi-Slot Die Coater Bolt Layout for Uniform Thick Electrode Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional slot die coaters face challenges in uniformly forming thick electrode active material layers due to deformation and twist, especially in multi-slot configurations, leading to non-uniform coating and reduced productivity.
Innovation Solution
A multi-slot die coater design with optimized bolt positioning and angled die block configurations minimizes deformation and twist by controlling slot gap deviations, ensuring uniform coating thickness and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple die blocks are assembled to form multi-slot configuration, then productivity is improved by simultaneous coating of multiple layers, but structural stability deteriorates leading to deformation and twist
Solution Approach 1:
The die assembly is divided into multiple separate die blocks (first die block, second die block, third die block) that can be individually manufactured and assembled. Each die block contains specific slots for coating different layers, allowing the system to handle multiple coating operations while maintaining manageable individual component sizes that are less prone to deformation.
Solution Approach 2:
The die blocks are arranged in a nested configuration where the first die block, second die block, and third die block are positioned sequentially along the coating path. This nested arrangement allows compact positioning of multiple coating functions while maintaining structural integrity through controlled spacing and alignment features.
2Manufacturing precision
If slot gap is adjusted to control coating thickness, then manufacturing precision is improved, but slot gap stability deteriorates due to sensitivity to fastening strength and pumping force
Solution Approach 1:
A support structure acts as an intermediary element between the die blocks and the coating substrate. This support structure provides a stable reference plane that maintains consistent slot gaps during operation, isolating the gap dimensions from variations in fastening strength and pumping forces. The support structure serves as a mediator that ensures uniform coating thickness despite external force variations.
3Device complexity
If die block thickness is reduced to minimize device footprint, then device complexity is reduced, but structural strength deteriorates making die blocks vulnerable to deformation
Solution Approach 1:
The die blocks are designed with non-uniform thickness distributions optimized for their specific functions. Critical regions such as areas surrounding slots and regions experiencing high stress concentrations are locally reinforced with increased thickness, while non-critical areas maintain reduced thickness to minimize overall device footprint. This local quality differentiation allows structural strength to be enhanced precisely where needed without increasing overall device complexity.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present disclosure provides a multi-slot die coater which fastens a contact surface between die blocks using bolts whose position is set to minimize the loading deviation. According to the present disclosure, it is possible to reduce deformation or twist of the die block having structural vulnerability, and thereby uniformly form a coating layer, in particular, an electrode active material layer at a desired thickness, and it is possible to coat at least two types of electrode active material slurries at the same time, thereby achieving high performance and productivity.