The coating process is one of the key processes in the manufacturing of lithium battery electrodes. The stability and consistency of the coating determine the structure of the electrode, which in turn affects the performance and cycle life of the battery. As large-sized power lithium battery products had higher requirements for coating width, one of the core technical issues is how to ensure the flow uniformity of electrode slurry at the outlet of the coating die. Therefore, rational design of the flow channel structure of the coating die is crucial. This study aims to address the issue of inhomogeneous velocity distribution at the outlet of the wide coating die, and constructs die head flow channel models with different sizes and structures for flow field simulation. The flow characteristics of electrode slurry inside the die head are analyzed, and the structural dimensions of the coat-hanger die are optimized by using Box-Behnken design. The coat-hanger die with an inclined variable-diameter homogenizing cavity had a stronger drainage effect on the slurry, helping to improve the flow uniformity in the width direction. Adjustments to the die structure dimensions significantly impacted flow uniformity. The main structural parameters of the coat-hanger die were optimized using Box-Behnken design, resulting in an increase in the uniformity of the slurry to 0.99.
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