Dual-Slit Die Coater Structure for Simultaneous Battery Electrode Coating
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Solution Overview
Problem
Conventional die coaters face inefficiencies in simultaneously coating current collectors for secondary batteries with two types of liquids, often resulting in liquid mixing and quality defects due to separate processing of electrode slurry and insulation coating liquid.
Innovation Solution
A die coater design featuring separate slits for each liquid, with coater shims of the same height that do not overlap vertically, and a pressurizing structure to maintain airtightness and prevent internal mixing, allowing for simultaneous and effective coating of an electrode slurry and insulation coating liquid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate processes are used to coat electrode slurry and insulation coating liquid, then quality defects are avoided, but production efficiency deteriorates
Solution Approach 1:
The die coater is divided into separate coating units, each responsible for a specific liquid (electrode slurry or insulation coating liquid). Each unit has its own slit and coater shim, allowing independent control and discharge of different liquids without mixing, thus maintaining quality while enabling simultaneous coating operations
Solution Approach 2:
Multiple coating functions are merged into a single die coater device. The device simultaneously discharges both electrode slurry and insulation coating liquid through separate slits onto the current collector in one operation, eliminating the need for separate coating processes and improving production efficiency
2Productivity
If independent slits are formed for each liquid in one die coater, then production efficiency is improved, but liquid mixing and quality defects occur
Solution Approach 1:
The die coater is segmented into distinct coating units with separate slits and coater shims for each liquid type. This physical segmentation prevents mixing between electrode slurry and insulation coating liquid while maintaining the ability to coat both simultaneously, thus preserving quality while improving efficiency
Solution Approach 2:
Coater shims act as intermediary elements that form sealed slits for each liquid discharge path. The shims with protruding guides create physical barriers and sealing mechanisms that prevent liquid leakage and mixing between separate coating channels, ensuring quality control in simultaneous coating operations
3Ease of operation
If coater shims are used to form slits and seal between blocks, then liquid discharge control is achieved, but liquid leakage and mixing occur
Solution Approach 1:
The sealing function is segmented into individual coater shims for each liquid discharge path. Each shim independently seals its own slit and prevents leakage, providing localized control and sealing that avoids cross-contamination between different liquid streams
Solution Approach 2:
Coater shims serve as intermediary sealing elements positioned between the upper and lower blocks. The shims with their specific geometric features (protruding guides, slot shapes) create effective seals that control liquid discharge while preventing leakage and mixing between adjacent coating channels
Data Source
AI summary
A die coater capable of effectively simultaneously coating a current collector with two types of different liquids, which includes an upper block provided with a second liquid inlet, a lower block coupled to the upper block and provided with a manifold configured to accommodates a first liquid, and coater shims interposed between the upper block and the lower block to form a first slit and a second slit which are separated from each other. The coater shims include a first coater shim which forms a first slit for discharging the first liquid accommodated in the manifold and a second coater shim which forms a second slit for discharging the second liquid supplied through the second liquid inlet. The first coater shim and the second coater shim have the same height, do not overlap vertically, and are placed on the same surface between the upper block and the lower block.