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Controlling Slot-Coating Edge Profiles of Battery Electrodes.

Jihwan Yoon¹, Kyengmin Min¹, Jisoo Song¹

¹Department of Chemical and Biological Engineering, Seoul National University, Seoul 08826, South Korea.

ACS Applied Materials & Interfaces

|December 1, 2025

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Controlling battery electrode edge profiles during slot-die coating is crucial for manufacturing. This study reveals that optimizing the gap between the slot-die and substrate to match wet coating thickness is key for high-quality electrodes.

Area of Science:

Materials Science
Chemical Engineering
Manufacturing Processes

Background:

Slot-die coating is vital for battery electrode manufacturing.
Controlling edge profiles is essential for high-quality electrodes and production yield.
Existing knowledge on thick-film electrode edge formation mechanisms is limited.

Purpose of the Study:

To investigate edge profile formation mechanisms in thick-film anode electrode slot-coating.
To identify strategies for controlling edge profiles during the slot-coating process.
To provide practical guidelines for optimizing slot-die coating parameters.

Main Methods:

Conducted over 500 experiments under diverse process conditions.
Employed statistical and machine learning analyses for data interpretation.

Keywords:

battery electrode edge profile process optimization slot-coating thick-film coating

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Utilized a visco-capillary model for theoretical analysis of physical mechanisms.

Main Results:

Edge profiles are primarily influenced by pressure distribution within the coating bead and downstream leveling flows.
Identified key process variables affecting edge profile formation.
Established a correlation between process parameters and edge quality.

Conclusions:

Optimal edge quality is achieved when the slot-die to substrate gap equals the wet coating thickness.
The findings offer practical insights for slot-die configuration and process control.
This research contributes to improving the manufacturing of high-quality battery electrodes.