Dual Slot Die Coater Push-Pull Gap Control Across Coating Width
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Solution Overview
Problem
Conventional dual slot die coaters face challenges in adjusting the coating gap and controlling widthwise deviation, leading to non-uniform coating of active material layers, especially when using different types of active material slurries, which affects the quality and productivity of secondary battery electrodes.
Innovation Solution
A dual slot die coater design featuring a plate member with adjustable bolts and spacers to control the coating gap, allowing precise manipulation of the upper and intermediate plates to maintain uniformity, even under high pressure, without disassembling the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the coating gap is adjusted by disassembling and reassembling die blocks, then the coating gap can be changed for different slurry types, but the device complexity increases and operation becomes difficult
Solution Approach 1:
The patent implements a dynamic coating gap adjustment mechanism where the intermediate die block can move relative to the lower and upper die blocks along the machine direction. This is achieved through a positioning mechanism that allows the intermediate block to be positioned at different locations, thereby changing the coating gap without disassembling the die blocks. The movable intermediate block creates a variable gap structure that adapts to different slurry types and coating requirements.
Solution Approach 2:
The die coater is segmented into three separate die blocks (lower, intermediate, and upper) that can be independently positioned. The intermediate die block is divided into multiple sections that can be independently adjusted, allowing precise control of the coating gap at different width positions. This segmentation enables flexible adjustment of the coating gap without requiring complete disassembly of the die structure.
2Adaptability or versatility
If the coating gap is adjusted by disassembling and reassembling die blocks, then the coating gap can be changed, but the operation time and productivity are reduced
Solution Approach 1:
The dynamic positioning mechanism allows the intermediate die block to be quickly repositioned along the machine direction without disassembly. The positioning mechanism includes a driving unit that can rapidly move the intermediate block to different locations, and a fixing unit that secures it in place. This dynamic adjustment system enables fast changeover between different coating gap settings, significantly reducing operation time and maintaining high productivity.
Solution Approach 2:
Multiple intermediate die blocks are pre-positioned at different locations along the machine direction, each corresponding to a specific coating gap setting. When a different slurry type or coating thickness is required, the system simply switches to a pre-positioned intermediate block rather than adjusting an existing one. This preliminary preparation of multiple positions eliminates the need for time-consuming disassembly and reassembly operations.
3Volume of moving object
If the die blocks are made thin to reduce footprint, then the device size is reduced, but the structural strength decreases causing deformation and torsion
Solution Approach 1:
The die coater is divided into three separate die blocks instead of using a single thick block. This segmentation allows each block to be thinner individually while maintaining overall structural integrity through their arrangement. The lower, intermediate, and upper die blocks are positioned to form a stable structure that resists deformation and torsion despite having reduced individual thickness, thus reducing the device footprint while preserving strength.
Solution Approach 2:
The die blocks are constructed using composite structures that combine materials with different properties to achieve both reduced thickness and maintained strength. The die blocks incorporate high-strength, low-weight materials and optimized internal structures that provide sufficient mechanical strength to resist deformation and torsion forces during operation, while keeping the overall device footprint compact.
4Manufacturing precision
If multiple intermediate die blocks are used to control widthwise gap deviation, then the coating uniformity is improved, but the device complexity increases
Solution Approach 1:
The intermediate die block is segmented into multiple independent sections along the width direction, each capable of being positioned at different locations in the machine direction. This segmentation allows independent adjustment of the coating gap at different width positions, enabling precise control of widthwise gap deviation. Each segment can be positioned to compensate for variations in coating requirements across the width of the substrate.
Solution Approach 2:
Different segments of the intermediate die block can be positioned at different locations to create locally optimized coating gaps. This allows the coating gap to be tailored for specific regions of the substrate width, addressing local variations in coating requirements. The positioning mechanism enables each segment to have a customized position, achieving local quality optimization for improved coating uniformity across the entire width.
Data Source
AI summary
There is provided a dual slot die coater that is easy to adjust a coating gap and can control a widthwise deviation of coating gap. The dual slot die coater of the present disclosure includes a plate member including a lower plate, an intermediate plate positioned on the lower plate and an upper plate positioned on the intermediate plate, wherein a lower slot is formed between the intermediate plate and the lower plate, and an upper slot is formed between the upper plate and the intermediate plate; a block provided on a rear surface of the plate member, wherein the block can be separated from or coupled to the plate member, or integrally formed with at least one plate of the plate member; a first bolt to push at least one plate of the plate member from the block as the first bolt passes through the block; and a second bolt to pull the at least one plate of the plate member toward the block as the second bolt passes through the block.