All-Solid-State Battery Electrode Manufacturing via Semi-Dry Process
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Solution Overview
Problem
Conventional methods for manufacturing all-solid-state battery electrodes face challenges in achieving high energy density and stability, particularly in achieving uniform thickness and large loading amounts of cathode active materials, with dry processes struggling to produce electrodes effectively.
Innovation Solution
A method involving the preparation of a binder solution with a first binder and solvent, mixing with electrode materials to form slurries, adding a second binder for kneading to achieve a clay state, and rolling to produce electrodes with a high loading of electrode active material, using specific binders and solvents to ensure uniformity and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a dry process is used to manufacture cathode, then large loading amount of cathode active material can be achieved, but uniform thickness cannot be obtained and binder floating occurs
Solution Approach 1:
The patent changes the physical state parameter of the binder from dry powder to solution form, and adjusts the solid content parameter dynamically during processing. By controlling the solid content to decrease during kneading (from 90-95% to 60-90%), the method achieves both high active material loading and uniform electrode thickness, resolving the contradiction between quantity and precision.
2Manufacturing precision
If conventional wet process is used, then uniform electrode can be manufactured, but large loading amount of cathode active material cannot be achieved
Solution Approach 1:
The patent applies preliminary action by adding the binder solution early in the mixing process and controlling the solid content to decrease during subsequent kneading. This preliminary binding action allows high initial solid content (90-95%) for high loading amount, while the decreasing solid content ensures uniform distribution and prevents binder floating, achieving both high quantity and precision.
3Quantity of substance
If solid content in slurry is high, then large loading amount of active material is achieved, but binder dispersibility and uniformity deteriorate
Solution Approach 1:
The patent applies dynamics by making the solid content a dynamic parameter that changes during the kneading process. The solid content decreases from 90-95% to 60-90% during kneading, which dynamically adjusts the slurry viscosity and binder dispersibility. This dynamic adjustment allows high initial loading amount while ensuring uniform binder distribution through improved dispersibility during processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the rapid and uniform manufacturing of thin-film electrodes with high active material loading, improving energy density and stability while avoiding issues like binder floating and non-uniform thickness.
Implementation Method 1
preparing a binder solution by dispersing a first binder in a solvent
Implementation Method 2
producing a first slurry by mixing the binder solution and the electrode material
Implementation Method 3
adding a second binder to the second slurry and kneading it to obtain a resultant material in a clay state
Implementation Method 4
producing the electrode by rolling the resultant material in the clay state
Data Source
AI summary
A method for manufacturing an electrode for all-solid-state batteries uses a wet binder and a dry binder.