Multi-Slot Die Coater Structure for Uniform Slot Gap Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Multi-slot die coaters are structurally vulnerable to deformation and torsion due to thin die blocks, leading to deviations in slot gaps and non-uniform coating, especially in the width direction, which affects the quality and productivity of electrode manufacturing for secondary batteries.
Innovation Solution
A multi-slot die coater design with specific angle and distance controls between die blocks, including a shortest distance of 10 mm between manifold and die block surfaces, to minimize deformation and torsion, ensuring uniform slot gaps and stable coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-slot die coater is used, then the device complexity is low, but the productivity is limited to one substrate per coating head
Solution Approach 1:
The coating head is divided into multiple independent slots (first slot, second slot, third slot, fourth slot), each capable of coating a substrate independently. This segmentation allows parallel processing of multiple substrates, increasing productivity from one substrate per coating head to multiple substrates simultaneously while maintaining manageable structural complexity through modular slot design.
Solution Approach 2:
The multi-slot coating head is designed to perform multiple coating operations simultaneously on different substrates. Each slot functions as an independent coating unit, allowing the single coating head to serve multiple substrates in parallel, thereby achieving universal applicability across multiple coating tasks without requiring separate coating heads for each substrate.
2Manufacturing precision
If coating heads are cleaned between substrates, then manufacturing precision is maintained, but loss of time occurs during cleaning operations
Solution Approach 1:
A purge channel is provided in the coating head that allows purge fluid to be directed into the slots before substrate coating begins. This preliminary purging action removes any residual coating material from previous substrates, ensuring coating uniformity is maintained while eliminating the need for time-consuming cleaning operations between substrates.
Solution Approach 2:
A purge fluid is introduced as an intermediary substance to clean the coating slots between substrate coatings. The purge fluid flows through the purge channel and into the slots, displacing residual coating material without requiring mechanical cleaning or disassembly of the coating head, thus maintaining precision while minimizing time loss.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design maintains a uniform slot gap within ±2% deviation, enabling high-quality, uniform coating of electrode active material layers, improving both performance and productivity in secondary battery manufacturing.
Implementation Method 1
a purge channel in communication with the slots and configured to direct purge fluid into the slots
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A multi-slot die coater has improved a deviation in a width direction of a slot gap caused by a structural feature including a thin die block. The multi-slot die coater including a lower slot and an upper slot includes a lower die block; an intermediate die block disposed on the lower die block to form the lower slot therebetween; and an upper die block disposed on the intermediate die block to form the upper slot therebetween, wherein the intermediate die block comprises a manifold that is a space provided from a first surface facing the upper die block toward a second surface that is an opposed surface of the first surface, accommodates a coating solution, and is communicatively connected to the upper slot, and wherein a shortest distance from distances from any points on a bottom surface of the manifold to any points on the second surface is equal to or greater than 10 mm.