Controlling Slot-Coating Edge Profiles of Battery Electrodes

Controlling edge profiles in slot-die coating is critical for high-quality battery electrode manufacturing, yet the underlying mechanisms remain inadequately understood, particularly for thick electrodes. The slot-coating process deposits a slurry containing active materials onto a current collector, which constitutes a fundamental step in battery electrode production. While widely used in industry, controlling electrode edge quality remains a challenge, as elevated edges can cause wrinkles and reduce production yield. This study investigates edge profile formation mechanisms and control strategies for thick-film anode electrode slot-coating processes through comprehensive experimental and theoretical analysis. More than 500 experiments across various process conditions were analyzed using statistical and machine learning methods, revealing key process variables and underlying physical mechanisms through a visco-capillary model. The results demonstrate that edge profiles depend primarily on pressure distribution within the coating bead and downstream leveling flows. Optimal edge quality is achieved when the gap between the slot-die and substrate equals the wet coating thickness, providing practical guidelines for slot-die configuration and process conditions in battery electrode manufacturing.