Shimmed Nozzle Assembly for Uniform Micron Adhesive Coating
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Solution Overview
Problem
Existing methods fail to achieve uniform and extremely thin adhesive coatings on electrode sheets of electric vehicle batteries, with current products unable to maintain a thickness of 10-20 µm and prone to defects like missing adhesive or uneven application, while also requiring zero tolerance for exposed metals and continuous coating performance.
Innovation Solution
A nozzle assembly with a lip plate, cover plate, and shim design, combined with a coating system including a metering assembly and heating block, to precisely control fluid distribution, achieving micron-level coatings through a slit nozzle with a shim and dam structure, reducing hydraulic pressure drop and eliminating fluid hammerheads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coating methods are used to apply adhesive to electrode sheets, then the coating process can be performed, but the adhesive thickness cannot be controlled uniformly at 10-20 μm and defects such as missing adhesive or uneven application occur
Solution Approach 1:
The patent introduces a precisely engineered nozzle assembly as an intermediary device between the adhesive source and the electrode sheet. The nozzle assembly includes a nozzle body with a controlled internal channel, a nozzle plate with a precisely positioned opening, and a distance control member that maintains a fixed gap between the nozzle plate and the electrode sheet surface. This intermediary structure ensures uniform adhesive distribution at the required 10-20 μm thickness without defects.
Solution Approach 2:
The patent controls the adhesive coating parameters by precisely defining the geometry of the nozzle components. The distance control member maintains a specific gap distance (10-20 μm) between the nozzle plate and the electrode sheet. The nozzle plate opening dimensions and the internal channel geometry are designed to control the adhesive flow rate and distribution pattern, ensuring uniform coating thickness and preventing defects.
2Productivity
If high production line speeds (up to 120 m/min) are used to replace traditional adhesive tape bonding, then productivity increases, but the coating uniformity and thickness control deteriorate
Solution Approach 1:
The patent designs the nozzle assembly to be dynamically stable at high speeds. The distance control member ensures that the gap between the nozzle plate and the electrode sheet remains constant even during high-speed movement (up to 120 m/min). The nozzle assembly can be quickly positioned and secured, allowing the system to maintain precision coating application during rapid production cycles.
Solution Approach 2:
The nozzle assembly is pre-configured with the correct gap distance and orientation before the coating process begins. The distance control member is pre-adjusted to maintain the required 10-20 μm gap, and the nozzle plate opening is pre-positioned to ensure proper adhesive distribution. This preliminary setup eliminates the need for real-time adjustments during high-speed production, maintaining coating uniformity at elevated speeds.
3Manufacturing precision
If the nozzle assembly components (lip plate, cover plate, shim) are designed with precise dimensions and fit tolerances, then coating precision improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The nozzle assembly is segmented into distinct functional components: a lip plate (or nozzle body) containing the adhesive channel, a cover plate with a precisely positioned opening, and a shim (distance control member) to maintain the gap. This segmentation allows each component to be manufactured and adjusted independently, simplifying the overall assembly process while maintaining precise coating control through the coordinated fit of the parts.
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
Enables precise and stable application of extremely thin adhesive layers, meeting the stringent requirements for electric vehicle battery coatings with improved responsiveness and reduced defects, suitable for high-speed production lines.
Implementation Method 1
the shim has a cutout extending upwards from a bottom side of the shim, and a height of a topmost portion of the cutout is greater than or equal to a height of a topmost portion of the lip plate channel of the lip plate
Data Source
Figure 1~2
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AI summary
The present application relates to a nozzle assembly and a coating system comprising the same. The nozzle assembly (5) comprises: a lip plate (51) that has a lip plate channel (51a) extending through the lip plate in a thickness direction of the lip plate and a receiving groove (51b) located on one side of the lip plate in the thickness direction and used for receiving a fluid from outside of the nozzle assembly, the lip plate channel (51a) and the receiving groove (51b) being in fluid communication with each other; a cover plate (52) that is connected to the lip plate on the other side of the lip plate (51) opposite to the receiving groove (51b); and a shim (53) that is located between the lip plate and the cover plate, wherein the shim has a cutout (53a) extending upwards from a bottom side of the shim, and a height of a topmost portion of the cutout is greater than or equal to a height of a topmost portion of the lip plate channel of the lip plate.