Experimental and numerical study on flow characteristics of dual‐cavity die based on multi‐objective optimization

Slot die coating is a common method of manufacturing electrodes for lithium‐ion batteries. In this paper, a multi‐objective optimization research on the geometry of dual‐cavity die is investigated based on the numerical simulation of lithium battery anode slurry flow combined with the surface response optimization method. First, we use the Plackett–Burman test method to screen the geometric parameters significantly affecting the optimization objective. Then, based on the Box–Behnken response surface analysis method, we determine the optimal combination of parameters. The results show that the inner cavity radius and slot gap are the main structural variables affecting exit‐velocity uniformity and die deformation. The slot gap and slot length mainly affect the inlet pressure. The coefficient of deviation of exit velocity uniformity and average inlet pressure of the optimized die structure decreased by 51.3% and 7.6%, respectively. This research provides theoretical guidance for the design of slot coating dies. Highlights Screening significant geometric parameters using Plackett–Burman test methodology. Box–Behnken response surface analysis to determine optimal parameters. Velocity uniformity and inlet pressure increased by 51.3% and 7.6%, respectively. Optimization and design of internal flow channel for dual‐cavity slot coating die.