Coating Die Head With Variable-Volume Cavity Pressure Control
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Solution Overview
Problem
The instability of pressure in the material cavity of coating die heads during the production of battery cells leads to fluctuations in coating weight, affecting the consistency of the coating process and causing material loss, reduced efficiency, and increased manufacturing costs.
Innovation Solution
A coating die head with adjustable cavity pressure adjusting blocks that can change volume to stabilize pressure, using regulating assemblies to convey or extract fluid, thereby adjusting the material cavity's volume and pressure online.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the coating die head operates with a fixed material cavity volume, then the structure is simple and easy to manufacture, but the pressure in the material cavity fluctuates causing coating weight inconsistency
Solution Approach 1:
The patent introduces a variable volume cavity structure where the cavity volume can be dynamically adjusted during operation. This is achieved through a movable cavity wall that can change the cavity volume in response to pressure changes, thereby maintaining stable coating weight without requiring a completely complex redesigned die head structure.
Solution Approach 2:
The patent changes the volume parameter of the material cavity from a fixed value to a variable value that can be adjusted according to operating conditions. By allowing the cavity volume to change, the system can compensate for pressure fluctuations and maintain consistent coating weight, resolving the contradiction between manufacturing precision and device complexity.
2Manufacturing precision
If the material cavity volume is increased to reduce pressure fluctuation, then coating weight consistency improves, but the device size and complexity increase
Solution Approach 1:
Instead of using a permanently large cavity volume, the patent employs a dynamic volume adjustment mechanism that allows the cavity to expand or contract as needed. This maintains coating consistency without requiring the die head to always occupy a larger volume, thus avoiding unnecessary increases in device size.
3Manufacturing precision
If the coating die head is replaced frequently to maintain coating quality, then coating weight consistency is maintained, but material loss increases and process efficiency decreases
Solution Approach 1:
The patent enables the die head to automatically adjust its own cavity volume in response to pressure changes, maintaining coating quality without requiring external intervention or replacement. This self-regulating capability eliminates the need for frequent die head replacements, thereby reducing material loss and improving process efficiency.
Solution Approach 2:
The patent implements a feedback mechanism where pressure changes in the material cavity trigger automatic volume adjustments. This closed-loop control ensures coating weight consistency is maintained continuously without requiring manual monitoring or replacement of the die head, thus improving productivity.
4Manufacturing precision
If the material cavity pressure is stabilized by increasing cavity volume, then coating weight consistency improves, but the response time to pressure changes decreases
Solution Approach 1:
The patent creates a dynamic system where the cavity volume can change rapidly in response to pressure fluctuations. The movable cavity wall is designed to respond quickly to pressure changes, maintaining both coating consistency and fast response time, unlike a statically large cavity that would respond slowly.
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
Stabilizes coating weight consistency, reduces material loss, improves process efficiency, and lowers manufacturing costs by allowing precise adjustment of pressure without frequent die head replacements.
Implementation Method 1
the cavity pressure adjusting block being configured to change a volume with a pressure change of the cavity
Implementation Method 2
the regulating assembly being adapted to communicate with the cavity through the through hole and being used for conveying fluid into the cavity or extracting fluid from the cavity to adjust the volume of the cavity pressure adjusting block by changing pressure of the cavity
Data Source
AI summary
A coating die head includes a die head body, a cavity pressure adjusting block and a regulating assembly. A material cavity is arranged in the die head body, and a first wall surface of the material cavity has a through hole. The cavity pressure adjusting block is arranged in the material cavity, the cavity pressure adjusting block comprises a cavity that is located inside the cavity pressure adjusting block, the cavity pressure adjusting block is configured to change a volume with a pressure change of the cavity, one side wall surface of the cavity pressure adjusting block facing towards the first wall surface is a second wall surface, and the second wall surface is fitted with the first wall surface and surrounds a region where the through hole is located. The coating die head may be integral to a coating equipment.