Multi-Row Slot-Die Flow Control for Uniform Dual-Layer Electrode Coating
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Solution Overview
Problem
Existing electrode coating systems face challenges in maintaining coating quality and productivity, particularly when increasing the width of the slot die or the coating thickness, which leads to dispersion in the loading level per unit area and decreased bonding force and conductivity.
Innovation Solution
A flow rate control apparatus and method that utilize a plurality of slot dies, pumps, valves, and flowmeters to precisely control the slurry flow rate, ensuring uniform coating across multiple rows by adjusting the supply amount and distribution of the slurry based on real-time measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the width of the slot die is increased to improve productivity, then the number of coating rows increases, but the coating quality degrades with increased dispersion of loading level per unit area
Solution Approach 1:
The patent divides the coating system into multiple independent coating units, each with its own pump and flow control mechanism. This segmentation allows each coating row to be controlled independently, maintaining uniform coating quality across multiple rows while preserving the productivity benefits of increased width.
Solution Approach 2:
The patent introduces dynamic flow rate control for each coating unit based on real-time measurements. The system adjusts the flow rate of slurry to each slot die dynamically to compensate for variations and maintain uniform coating thickness across all rows, resolving the quality issue while keeping productivity high.
2Quantity of substance
If the coating thickness is increased, then the coating amount increases, but the quality of the electrode degrades with decreased bonding force and conductivity
Solution Approach 1:
The patent applies different coating thicknesses to different regions or rows based on specific requirements. By controlling the flow rate of each coating unit independently, the system can optimize the coating amount locally to achieve sufficient coverage while preventing excessive thickness that would harm bonding force and conductivity.
Solution Approach 2:
The patent changes the flow rate parameter dynamically for each coating unit to achieve the optimal coating thickness. By adjusting the slurry flow rate, the system controls the coating amount precisely, ensuring adequate coverage without exceeding the threshold that would degrade electrode quality.
3Productivity
If multiple coating rows are coated simultaneously to improve productivity, then output increases, but uniform control of coating amount becomes more difficult
Solution Approach 1:
The patent segments the coating system into multiple independently controlled units, each with its own pump and flow meter. This allows simultaneous operation of multiple coating rows for high productivity while maintaining uniform control through independent monitoring and adjustment of each unit's coating amount.
Solution Approach 2:
The patent implements feedback control by measuring the flow rate of slurry to each coating unit with a flow meter and using this information to adjust the coating process. This feedback mechanism ensures uniform coating control across all rows operating simultaneously, maintaining precision while achieving high output.
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 solution stabilizes the electrode coating process, improves coating quality by ensuring uniform coating amounts, and enhances productivity by simplifying the system structure and reducing manufacturing costs.
Implementation Method 1
a flowmeter which measures a flow rate of the slurry supplied to the plurality of slot dies
Implementation Method 2
a pump which supplies the slurry from a tank to each of the upper layer and the lower layer
Implementation Method 3
a valve which is installed in (or at) the plurality of slot dies, divides the slurry supplied from the pump, and supplies the divided slurry to the plurality of slot dies
Implementation Method 4
a plurality of slot dies which are formed as an upper layer and a lower layer and coat an electrode with a slurry
Data Source
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AI summary
The present invention relates to a flow rate control apparatus (200) and method for coating multi-division dual layers. A flow rate control apparatus (200) according to the present invention includes a plurality of slot dies (310, 311) which are formed as an upper layer (A) and a lower layer (B) and coat an electrode with slurry, a pump (290, 291, 292) which supplies the slurry from a tank (300) to each of the upper layer (A) and the lower layer (B), a valve (260, 261, 262, 263, 264, 265, 266) which is installed in the plurality of slot dies (310, 311), divides the slurry supplied from the pump (290, 291, 292), and supplies the divided slurry to the plurality of slot dies (310, 311), a flowmeter (250, 251, 252, 253, 254, 255, 256) which measures a flow rate of the slurry supplied to the plurality of slot dies (310, 311), and a processor (210) which controls the pump (290, 291, 292) and the valve (260, 261, 262, 263, 264, 265, 266) on the basis of the flow rate of the slurry measured by the flowmeter (250, 251, 252, 253, 254, 255, 256) to control a coating amount of the electrode.