Patent Description:
As energy prices are increasing due to the depletion of fossil fuels and increasing attention is being paid to environmental pollution, the demand for environmentally-friendly alternative energy sources acts as an essential factor for future life. Thus, research into techniques for generating various kinds of power, such as nuclear energy, solar energy, wind energy, and tidal power, is underway, and power storage apparatuses for more efficient use of the generated energy are also drawing much attention.

Moreover, the demand for batteries as energy sources is rapidly increasing as mobile device technology continues to develop and the demand for such mobile devices continues to increase. Accordingly, much research on batteries capable of satisfying various needs has been carried out. In particular, in terms of the material for batteries, the demand for lithium secondary batteries, such as lithium ion batteries and lithium ion polymer batteries, which have advantages such as high energy density, discharge voltage, and output stability, is very high.

A secondary battery includes an electrode assembly having a structure, in which an anode, a cathode, and a separator interposed between the anode and the cathode are stacked, and the electrode assemblies are received in a pouch case, a cylindrical shape can, a prismatic case, and the like depending on the purpose of use to manufacture the battery.

The anode and the cathode are manufactured by coating an anode slurry and a cathode slurry onto an electrode collector formed of aluminum foil and copper foil, and drying the anode slurry and the cathode slurry, respectively. In order to make the charge and discharge characteristics of the secondary battery uniform, an anode active material slurry and a cathode active material slurry have to be uniformly coated on the collector, and a slot die coating process is commonly performed to achieve this.

<FIG> is a longitudinal sectional view illustrating a slot die coating apparatus according to the related art, which is used in a process of coating a single layer active material. <FIG> is a longitudinal sectional view illustrating a slot die coating apparatus according to the related art, which is used in a process of coating a multilayer active material.

The slot die coating apparatus <NUM> includes a slot die <NUM>, from which the electrode active material slurry is discharged, and a coating roller <NUM>. The slot die <NUM> includes two die blocks 11a and 11b, and a discharge opening <NUM>, from which the electrode active material slurry (not illustrated) is discharged, is formed between a first die block 11a and a second die block 11b. The electrode active material slurry discharged from the discharge opening <NUM> is applied to one surface of the collector <NUM> while the coating roller <NUM> rotates.

If necessary, an electrode active material layer constituting an additional layer is additionally applied onto an electrode active material layer constituting a single layer to form an electrode active material layer having two layers. In order to form the electrode active material layer having two layers, the slot die <NUM> including four die blocks 21a, 21b, 21c, and 21d as illustrated in <FIG> is used. The slot die <NUM> may continuously apply an additional electrode active material slurry onto the electrode active material slurry applied in advance by simultaneously discharging the electrode active material slurry through two discharge openings <NUM> and <NUM> formed between die blocks 21a, 21b, 21c, and 21d, which are adjacent to each other.

<FIG> is a picture illustrating contamination of an uncoated area, which is caused when intermittent coating is performed by using the slot die coating apparatus in <FIG> and <FIG>.

Referring to <FIG> and <FIG>, the uncoated area <NUM>, in which the electrode active material slurry is not coated, is formed in the collector <NUM>, when fully intermittent coating is performed by using the slot die coating apparatuses <NUM> and <NUM>. Then, when bubbles are present in the electrode active material slurry, the bubbles burst while being discharged from the discharge openings <NUM>, <NUM>, and <NUM> in a section, in which the uncoated area <NUM> is formed. Then, contamination, in which the electrode active material slurry surrounding the bubbles is partially coated to the uncoated area <NUM> like a mottle <NUM>, is caused.

In a process of coating an electrode active material, because a distance between the discharge openings <NUM>, <NUM>, and <NUM> and the collector <NUM> is generally a distance D of <NUM> to <NUM>, the above-mentioned contamination is caused by fine bubbles.

Accordingly, it is urgently necessary to develop a slot die coating apparatus having an improved structure that can solve the above-mentioned problems.

Document <CIT> relates to a coating die and coating machine.

Document <CIT> pertains to a slot die for improving coating uniformity.

Document <CIT> describes a slit nozzle for a slit coater and a system for supplying a chemical solution using the same.

It is an object of the present disclosure to provide a slot die coating apparatus that can prevent an uncoated area section from being contaminated by electrode active material slurry in a process of intermittently coating an electrode active material.

However, the problem to be solved by the embodiments of the present disclosure is not limited to the above-described problems, and can be variously expanded within the scope of the technical idea included in the present disclosure.

A slot die coating apparatus according to an embodiment of the present disclosure is defined in claim <NUM>.

The upper die may include a first upper die, a second upper die, and an upper spacer.

The upper discharge opening may be formed by sequentially coupling the first upper die, the upper spacer, and the second upper die.

An upper slurry receiving part may be formed in the second upper die.

The upper slurry receiving part may be communicated with the upper discharge opening.

The upper air vent may pass through the first upper die to be communicated with the upper slurry receiving part.

The lower die may include a first lower die, a second lower die, and a lower spacer.

The lower discharge opening may be formed by sequentially coupling the first lower die, the lower spacer, and the second lower die.

A lower slurry receiving part may be formed in the second lower die.

The lower air vent may pass through the first upper die, the second upper die, and the first lower die to be communicated with the lower slurry receiving part.

The upper spacer may include a first opening and may be interposed in only the remaining part except for one side of a peripheral area in which the first upper die and the second upper die face each other.

The lower air vent may be installed to pass through the upper spacer.

The upper air vent and/or the lower air vent may include a valve.

As described above, the slot die coating apparatus according to the embodiments of the present disclosure can remove bubbles included in the electrode active material slurry introduced into the discharge opening by installing the air vent in the slot die.

Hereinafter, various embodiments of the present disclosure will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily implement them. The present disclosure may be modified in various different ways, and is not limited to the embodiments set forth herein.

Further, throughout the specification, when a part is referred to as "including" a certain component, it means that it can further include other components, without excluding the other components, unless otherwise stated.

<FIG> is a schematic diagram illustrating a slot die coating apparatus according to an embodiment of the present disclosure. <FIG> is a longitudinal sectional view when a vertical section along dotted line A of <FIG> is viewed from direction C.

Referring to <FIG> and <FIG>, the slot die coating apparatus <NUM> includes a slot die <NUM>, a coating roller <NUM>, and an air vent <NUM>. The slot die coating apparatus <NUM> is used to simultaneously coat and fix two electrode active material layers.

The slot die <NUM> includes an upper die 101A and a lower die 101B. The upper die 101A includes a first upper die 101A-<NUM>, a second upper die 101A-<NUM>, and an upper spacer <NUM>. The second upper die 101A-<NUM> may have an inclined structure, in which a surface of the second upper die 101A-<NUM>, which faces a first lower die 101B-<NUM>, has the angle of approximately <NUM> to <NUM> degrees with respect to the ground surface.

The second upper die 101A-<NUM> may include a recessed upper slurry receiving part <NUM>, which has a predetermined depth on a surface of the second upper die 101A-<NUM>, which faces the first upper die 101A-<NUM>. The upper slurry receiving part <NUM> may be connected to an upper slurry supply chamber (not illustrated) installed on the outside to continuously receive a first electrode active material slurry. The upper slurry receiving part <NUM> may include an upper slurry supply port <NUM> communicated with the upper slurry supply chamber (not illustrated).

If the upper slurry receiving part <NUM> is fully filled with the first electrode active material slurry supplied through the upper slurry supply port <NUM>, the first electrode active material slurry moves in a direction, in which the coating roller <NUM> is installed, through an upper discharge opening <NUM> formed by sequentially coupling the second upper die 101A-<NUM>, the upper spacer <NUM>, and the first upper die 101A-<NUM> to be discharged to the outside. That is, the upper spacer <NUM> is interposed between the first upper die 101A-<NUM> and the second upper die 101A-<NUM> to form a gap between the first upper die 101A-<NUM> and the second upper die 101A-<NUM> so as to form a space, into which the first electrode active material slurry supplied from the upper slurry receiving part <NUM> can be discharged.

The first upper die 101A-<NUM> is located on the upper side of the second upper die 101A-<NUM> and is coupled to the second upper die 101A-<NUM> while the upper spacer <NUM> being interposed therebetween. A surface of the first upper die 101A-<NUM>, which faces the second upper die 101A-<NUM>, may be formed in parallel to the ground surface.

An upper surface of the first upper die 101A-<NUM> may be classified into two areas. The upper surface of the first upper die 101A-<NUM> may include a flat portion <NUM> located relatively far away from the upper discharge opening <NUM> and an inclined portion <NUM> extending from the flat portion <NUM>. The flat portion <NUM> extends to be parallel to the ground surface and the inclined portion <NUM> is obliquely inclined to the lower side while having an angle of approximately <NUM> to <NUM> degrees with respect to the flat portion <NUM>.

The first upper die 101A-<NUM> and the second upper die 101A-<NUM> may be formed of a metal material, and the first upper die 101A-<NUM> and the second upper die 101A-<NUM> may be mutually coupled to each other through bolting and the like.

<FIG> is a plan view illustrating the upper spacer of <FIG>.

Referring to <FIG>, the upper spacer <NUM> may have a substantially stapler-shaped planar shape. Accordingly, the upper spacer <NUM> has a first opening 123a formed on one side thereof to be interposed in only the remaining parts of a periphery thereof, at which the first upper die 101A-<NUM> and the second upper die 101A-<NUM> face each other, except for one side thereof. Further, the first upper die 101A-<NUM> and the second upper die 101A-<NUM> are spaced apart from each other in an area, in which the first opening 123a is formed, to form the upper discharge opening <NUM> and the upper discharge opening <NUM> is communicated with the upper slurry receiving part <NUM>.

Because the upper spacer <NUM> functions as a gasket such that the first electrode active material slurry is not leaked through an aperture between the first upper die 101A-<NUM> and the second upper die 101A-<NUM>, except for the area in which the upper discharge opening <NUM> is formed, it is preferable that the upper spacer <NUM> is formed of a material having an elasticity that can secure sealing performance.

A through-hole 123b, through which a lower air vent 103B passes, is formed in the upper spacer <NUM>. A detailed description of the lower air vent 103B will be described below.

<FIG> is a longitudinal sectional view when a vertical section along dotted line B of <FIG> is viewed from direction C.

Referring to <FIG> and <FIG>, the lower die 101B includes a first lower die 101B-<NUM>, a second lower die 101B-<NUM>, and a lower spacer <NUM>. The second lower die 101B-<NUM> is located on the lowermost side among dies constituting the slot die <NUM>, and may be inclined such that a surface of the second lower die 101B-<NUM>, which faces the first lower die 101B-<NUM>, has an angle of approximately <NUM> to <NUM> degrees with respect to the ground surface.

The second lower die 101B-<NUM> may include a recessed lower slurry receiving part <NUM>, which has a predetermined depth on the surface of the second lower die 101B-<NUM>, which faces the first lower die 101B-<NUM>. The lower slurry receiving part <NUM> may be connected to a lower slurry supply chamber (not illustrated) to continuously receive a second electrode active material slurry. The lower slurry receiving part <NUM> may include a lower slurry supply port <NUM> communicated with the lower slurry supply chamber. The first electrode active material slurry and the second electrode active material slurry may be formed of the same component or be formed of different components according to the purpose of the manufactured electrode.

If the lower slurry receiving part <NUM> is fully filled with the second electrode active material slurry supplied through the lower slurry supply port <NUM>, the second electrode active material slurry may be discharged to the outside through a lower discharge opening <NUM> formed by sequentially coupling the second lower die 101B-<NUM>, the lower spacer <NUM>, and the first lower die 101B-<NUM>.

The first lower die 101B-<NUM> is located on the upper side of the second lower die 101B-<NUM> and is coupled to the second lower die 101B-<NUM> while the lower spacer <NUM> being interposed therebetween. The first lower die 101B-<NUM> and the second lower die 101B-<NUM> may be inclined such that surfaces of the first lower die 101B-<NUM> and the second lower die 101B-<NUM>, which face each other, have an angle of approximately <NUM> to <NUM> degrees with respect to the ground surface.

The first lower die 101B-<NUM> may be obliquely inclined while an upper surface of the first lower die 101B-<NUM>, which faces the upper die 101A, has an angle of approximately <NUM> to <NUM> degrees with respect to the ground surface. In this way, the upper surface of the first lower die 101B-<NUM> is inclined with respect to the ground surface, and may be matched with the upper die 101A having a lower surface of a shape corresponding to the upper surface of the first lower die 101B-<NUM>.

The first lower die 101B-<NUM> and the second lower die 101B-<NUM> may be formed of a metal material, and may be mutually coupled to each other through bolting and the like.

<FIG> is a plan view illustrating the lower spacer of <FIG>.

Referring to <FIG> and <FIG>, the lower spacer <NUM> is interposed between the first lower die 101B-<NUM> and the second lower die 101B-<NUM> to form a gap between the first lower die 101B-<NUM> and the second lower die 101B-<NUM> so as to form a space, into which the second electrode active material slurry is discharged.

Accordingly, the lower spacer <NUM> has a first opening 113a formed on one side thereof to be interposed in only the remaining parts of peripheries of surfaces of the first lower die 101B-<NUM> and the second lower die 101B-<NUM>, which face each other, except for one side thereof. Further, the first lower die 101B-<NUM> and the second lower die 101B-<NUM> are spaced apart from each other in an area, in which the second opening 113a is formed, to form the lower discharge opening <NUM> and the lower discharge opening <NUM> is communicated with the lower slurry receiving part <NUM>.

Because the lower spacer <NUM> functions as a gasket such that the second electrode active material slurry is not leaked through an aperture between the first lower die 101B-<NUM> and the second lower die 101B-<NUM>, except for the area, in which the lower discharge opening <NUM> is formed, it is preferable that the lower spacer <NUM> is formed of a material having an elasticity that can secure sealing performance.

Referring to <FIG> and <FIG>, the air vent <NUM> includes the upper air vent 103A and the lower air vent 103B. The upper air vent 103A passes through the first upper die 101A-<NUM> to be communicated with the upper slurry receiving part <NUM>. Accordingly, before the first electrode active material slurry in the upper slurry receiving part <NUM> is introduced into the upper discharge opening <NUM>, bubbles in the first electrode active material slurry may be removed through the upper air vent 103A.

Because the upper discharge opening <NUM> is formed in parallel to the ground surface, even though the upper air vent 103A is communicated with any location of the upper slurry receiving part <NUM>, bubbles included in the first electrode active material slurry may be easily discharged to the outside through the upper air vent 103A. Meanwhile, it is preferable that the upper air vent 103A is installed in a direction that is perpendicular to a direction, in which the first electrode active material slurry is discharged, and which is opposite to a direction, in which gravity is applied, so as to efficiently remove bubbles included in the first electrode active material slurry.

<FIG> is a plan view illustrating that the upper spacer is located on an second upper die. The location of the upper air vent 103A is indicated for convenience of description.

Referring to <FIG> and <FIG>, the upper air vent 103A may be formed at rear side portions of an area formed in the upper slurry receiving part <NUM> in the first opening 123a of the upper spacer <NUM> when the second upper die 101A-<NUM> is viewed from the top. Here, "the rear side" refers to an opposite direction to a direction, in which the first electrode active material slurry is discharged. Then, "the side surface" refers to opposite portions in the lengthwise direction of the second upper die 101A-<NUM>, which are perpendicular to a direction, in which the first electrode active material slurry is discharged. Through the structure, the location of the upper air vent 103A does not hinder the operator's movements and facilitates the maintenance and repair of the slot die coating apparatus <NUM>.

Referring to <FIG>, the lower air vent 103B passes through the first upper die 101A-<NUM>, the second upper die 101A-<NUM>, and the first lower die 101B-<NUM> to be communicated with the lower slurry receiving part <NUM>. Accordingly, before the second electrode active material slurry in the lower slurry receiving part <NUM> is introduced into the lower discharge opening <NUM>, bubbles included in the second electrode active material slurry may be removed through the lower air vent 103B.

Because the lower discharge opening <NUM> is inclined at an angle of <NUM> to <NUM> degrees with respect to the ground surface and has a structure, in which the second electrode active material slurry is supplied to lower slurry receiving part <NUM> in an opposite direction to the gravitational force in the lower slurry port <NUM>, the largest number of bubbles are generated in portion S of the lower slurry receiving part <NUM>, which is connected to the lower discharge opening <NUM>. Accordingly, it is preferable that the lower air vent 103B is installed in portion S.

Further, it is preferable that the angle between the lower air vent 103B and the lower discharge opening <NUM> is maintained at <NUM> to <NUM> degrees.

<FIG> is a plan view illustrating that the lower spacer is located on a second lower die. The location of the lower air vent 103B is indicated for convenience of description. <FIG> is a plan view of a slot die of <FIG>. For convenience of description, a boundary of the first opening 123a of the upper spacer <NUM> is indicated by an alternate long and short dash line, and a boundary of the second opening 113a of the lower spacer <NUM> is indicated by a dotted line.

Referring to <FIG>, <FIG>, and <FIG>, it is preferable that the lower air vent 103B is installed not to pass through the upper discharge opening <NUM> and the upper slurry receiving part <NUM>. When the lower air vent 103B passes through portions, at which the upper discharge opening <NUM> and the upper slurry receiving part <NUM> are formed, it may hamper flows of the first electrode active material slurry and bubbles may be formed at the passing -through portions. Accordingly, it is preferable that the lower air vent 103B is formed to pass through the location, at which the upper spacer <NUM> deviates from the first opening 123a. For an example, the length W1 of the first opening 123a of the upper spacer <NUM> is formed to be smaller than the length W2 of the second opening 113a of the lower spacer <NUM> so that the lower air vent 103B may be formed to pass through the through-hole 123b of the upper spacer <NUM>.

The lower air vent 103B may be formed at portions that are close to side surfaces of the first upper die 101A-<NUM> in the lengthwise direction of the first upper die 101A-<NUM>, which is perpendicular to a direction, in which the second electrode active material slurry is discharged. The location of the lower air vent 103B does not hamper the operator's movements and facilitates the maintenance and repair of the slot die coating apparatus <NUM>.

In addition to the embodiment illustrated in <FIG>, the lower air vent 103B may be formed in various directions. As an example, the lower air vent 103B may pass through the second upper die 101A-<NUM> and the first lower die 101B-<NUM> to be formed in a rearward direction thereof (see D of <FIG>). In this case, because the lower air vent 103B does not pass through the upper spacer <NUM>, it may be installed at various locations on lateral sides. Further, the lower air vent 103B may be also formed on lateral sides.

<FIG> is a longitudinal sectional view illustrating a modification of <FIG>.

Referring to <FIG> and <FIG>, a slot die coating apparatus <NUM> may have a structure, in which an upper air vent 203A is bent in an inverse L shape. When bubbles included in the first electrode active material slurry of a low viscosity are removed, the bubbles are discharged together with the first electrode active material slurry. Then, the operator may easily receive the first electrode active material slurry that flows down through the bent upper air vent 203A. Although <FIG> illustrates only the bent structure that is bent in an inverse L shape, as long as the first electrode active material slurry flowing down may be easily received, the upper air vent 203A may be bent in various shapes.

Further, the upper air vent 203A may include a valve <NUM>. As long as the valve <NUM> has any structure that may open and close a hollowed pipeline, it is not specifically limited.

The slot die coating apparatus <NUM> may have the same structure as the slot die coating apparatus <NUM> of <FIG>, except for the structure, in which the upper air vent 203A is bent in an inverse L shape, and includes the valve <NUM>. Accordingly, a description of other configurations will be omitted.

Referring to <FIG> and <FIG>, a slot die coating apparatus <NUM> may have a structure, in which a lower air vent 203B is bent in an inverse L shape. When bubbles included in the second electrode active material slurry are removed, the bubbles are discharged together with the second electrode active material slurry. Then, the operator may easily receive the second electrode active material slurry that flows down through the bent lower air vent 203B. Although <FIG> illustrates only a structure that is bent in an inverse L shape, as long as the second electrode active material slurry running down may be easily received, the lower air vent 203B can be bent in various shapes.

Further, the lower air vent 203B may include a valve <NUM>. As long as the valve <NUM> has any structure that may open and close a hollowed pipeline, it is not specifically limited.

The slot die coating apparatus <NUM> may have the same structure as the slot die coating apparatus <NUM> of <FIG>, except for a structure, in which the lower air vent 203B is bent in an inverse L shape, and includes the valve <NUM>. Accordingly, a description of other configurations will be omitted.

An installation structure of air vents <NUM>, 203A, and 203B according to the present disclosure may be applied to the slot die coating apparatus used in a process of coating a single layer active material in <FIG>. In this case, it may be formed as in the upper air vent 103A of <FIG>. The relevant structure has already been described and will be omitted here.

Further, the installation structure of air vents <NUM>, 203A, and 203B according to the present disclosure may be applied to a <NUM>-stage slot die coating apparatus, in which the second upper die 101A-<NUM> and the first lower die 101B-<NUM> are integrally formed. It may have the same structure as <FIG>, <FIG>, <FIG>, and <FIG>, except for a structure, in which the second upper die 101A-<NUM> and the first lower die 101B-<NUM> are integrally formed.

Further, the slot die coating apparatuses <NUM> and <NUM> according to the present disclosure may prevent contamination of the uncoated area, which is caused when intermittent coating is performed, and may also solve non-coating of an active material caused due to continuous coating. When the electrode active material slurry including bubbles is applied to an electrode in the continuous coating process, if the bubbles surrounded by slurry burst, a portion, at which the active material is not coated, is caused in the spot, such as a crater, at which the bubbles was present. In the slot die coating apparatuses <NUM> and <NUM> according to the present disclosure, because bubbles included in the electrode active material slurry are removed through the air vents <NUM>, 203A, and 203B before the electrode active material slurry is discharged to the discharge openings <NUM> and <NUM>, the non-coating of the active material can be solved.

Claim 1:
A slot die coating apparatus (<NUM>) for coating an electrode active material slurry onto an electrode collector, the slot die coating apparatus comprising:
a coating roller (<NUM>);
a lower die (101B) comprising a lower discharge opening (<NUM>), through which a second electrode active material slurry is discharged, and a lower slurry receiving part (<NUM>) communicated with the lower discharge opening (<NUM>); and
an upper die (101A) located on the upper side of the lower die and having an upper discharge opening (<NUM>), through which a first electrode active material slurry is discharged,
wherein an upper air vent (103A) is installed in the upper die (101A) and a lower air vent (103B) is installed in the lower die (101B),
characterised in that
the lower air vent (103B) is formed at the portion (S), at which the lower slurry receiving part (<NUM>) and the lower discharge opening (<NUM>) are connected to each other.