Battery Electrode Delamination by Binder Softening and Pulverization
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Solution Overview
Problem
Existing battery processing methods consume excessive thermal energy and emit significant carbon dioxide due to high-temperature heating, which degrades binders and imposes environmental burdens.
Innovation Solution
A battery processing method that involves preparing a pulverized piece with an electrode substrate and active material layer, heating it at a temperature between the degradation starting and peak temperatures of the resin component to soften it, and then pulverizing it to peel the active material layer, thereby reducing thermal energy consumption and carbon dioxide emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating is carried out at 400°C to 550°C to degrade the binder, then the active material layer can be separated from the electrode substrate, but a great amount of thermal energy is consumed and carbon dioxide is emitted
Solution Approach 1:
The patent changes the temperature parameter from high-temperature degradation (400-550°C) to low-temperature softening (100-200°C), achieving effective separation while dramatically reducing thermal energy consumption and CO2 emissions
Solution Approach 2:
The patent applies preliminary mechanical pulverization to reduce the binder layer thickness before heating, which reduces the thermal energy required for softening and subsequent separation of the active material layer
2Reliability
If heating is carried out at 400°C to 550°C to degrade the binder, then the active material layer can be separated from the electrode substrate, but a large amount of binder is degraded and carbon dioxide is emitted
Solution Approach 1:
The patent changes the temperature parameter from high-temperature degradation (400-550°C) to low-temperature softening (100-200°C), achieving effective separation while dramatically reducing thermal energy consumption and CO2 emissions
Solution Approach 2:
The patent converts the harmful high-temperature degradation process into a beneficial low-temperature softening process, where the binder's softening property is utilized for separation rather than its degradation, thereby converting potential waste into a useful separation mechanism
3Reliability
If the pulverized piece is pulverized after heating, then the active material layer can be peeled from the electrode substrate, but the process requires multiple steps increasing complexity
Solution Approach 1:
The patent merges the heating and pulverization steps into a single integrated process where mechanical pulverization is applied during the heating phase, reducing the total number of process steps while maintaining high peeling efficiency
Solution Approach 2:
The patent applies preliminary mechanical pulverization to reduce the binder layer thickness before heating, which reduces the thermal energy required for softening and subsequent separation of the active material layer
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 efficiently peels the active material layer from the electrode substrate with reduced environmental impact, achieving a high peeling rate of 80% or more while minimizing thermal energy use and carbon dioxide emission.
Implementation Method 1
heating is carried out at a temperature not lower than a degradation starting temperature of the resin component and lower than a degradation peak temperature of the resin component, and thereby the resin component is softened
Data Source
AI summary
A battery processing method comprises: a preparation step to prepare a pulverized piece including an electrode substrate and an active material layer, the active material layer including a resin component and being provided on the electrode substrate; a heating step to heat the pulverized piece at a temperature not lower than a degradation starting temperature of the resin component and lower than a degradation peak temperature of the resin component; and a pulverization step to pulverize the pulverized piece, wherein in the heating step, the resin component is softened, and, in the pulverization step, the pulverized piece in a state where the resin component has been softened is pulverized and thereby the active material layer is peeled from the electrode substrate.