Multi-Slot Die Coater Step Block for Widthwise Gap Uniformity
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Solution Overview
Problem
Existing multi-slot die coaters face challenges in maintaining uniform coating gaps, particularly in the widthwise direction, which affects the thickness and uniformity of active material layers in secondary battery electrodes.
Innovation Solution
The multi-slot die coater configuration includes a lower die block, an intermediate die block, and an upper die block, with a fixing block having a step portion that couples the die blocks, maintaining a consistent coating gap and reducing widthwise deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dual slot die coater increases in width to use a wide current collector in order to increase the production amount, then productivity is improved, but it becomes more difficult to achieve uniform coating in the widthwise direction and coating gap control precision deteriorates
Solution Approach 1:
The die coater is divided into multiple die blocks (first die block, second die block, third die block) that can be independently adjusted. Each die block has its own coating gap control mechanism, allowing localized precision control across the width of the current collector. This segmentation enables the system to maintain uniform coating quality while processing wider substrates for increased productivity.
2Ease of operation
If the coating gap is not uniformly controlled in the widthwise direction, then device operation is simpler, but coating quality deteriorates with non-uniform thickness and poor boundary shape
Solution Approach 1:
The die blocks are designed with adjustable mechanisms that allow dynamic control of coating gaps in the widthwise direction. The coating gaps can be adjusted during operation to maintain uniformity across different sections of the current collector. This dynamic adjustability ensures high coating quality while maintaining operational flexibility and simplicity.
3Ease of manufacture
If multiple die blocks are assembled without precise positioning structures, then device assembly is easier, but coating gap deviation occurs due to assembly errors
Solution Approach 1:
Positioning structures such as positioning protrusions and positioning grooves are introduced as intermediary elements between die blocks. These positioning features act as mediators that automatically align and fix the relative positions of adjacent die blocks during assembly. This eliminates the need for complex manual positioning while ensuring consistent coating gap precision across all die blocks.
Data Source
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AI summary
There is provided a multi-slot die coater that is easy to adjust a coating gap and can achieve widthwise deviation control of the coating gap. According to a configuration of the present disclosure, a step is formed between rear surfaces of die blocks through a fixing block having a step portion. The fixing block has the step portion of a preset height, and any one die block is coupled to the step portion and the other die block is coupled to the other portion than the step portion, and thus the step is naturally formed between the rear surfaces of the die blocks by the coupling of the die blocks to the fixing block. Thus, it is possible to always maintain the distance of the front ends of the die blocks and the substrate, i.e., the coating gap at a desired level, and since the fixing block is fixed between the die blocks, once it is set, the coating gap does not change and is maintained during the process, thereby suppressing the widthwise coating gap deviation.