Multi-Layer Battery Coating with Continuous Bilayer Deposition
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Solution Overview
Problem
Existing multi-layer coating processes for lithium-ion batteries are inefficient due to repeated and redundant steps, leading to increased process time and potential material waste.
Innovation Solution
A method and system for continuously forming layers in lithium-ion batteries using a multi-layer coating system that sequentially deposits a wet coating and a free-standing material layer onto a moving substrate, followed by heat roll pressing to form a second bilayer with a partially dried and adhered wet coating-derived layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple coating steps are used to form dual-layer coating, then coating performance and active material tailoring are improved, but process time increases by at least a factor of two
Solution Approach 1:
The patent combines multiple coating steps into a single continuous coating process. The system applies different active materials to different regions of the electrode in one continuous operation, eliminating the need for separate coating steps that would otherwise be required to achieve the same multi-layer structure. This merging of operations maintains high manufacturing precision while significantly reducing process time.
Solution Approach 2:
The coating process operates continuously without interruption between layers. The system maintains continuous motion of the substrate through the coating head, applying different materials in sequence without stopping or resetting the process. This continuity eliminates idle time between coating steps while preserving the ability to create precisely controlled multi-layer structures with different active materials.
2Manufacturing precision
If repeated coating processes are used for multi-layer coating, then coating performance is improved, but material waste and processing inefficiencies increase
Solution Approach 1:
By merging multiple coating operations into one continuous process, the system eliminates redundant material application and removal cycles. Different active materials are deposited directly onto their designated regions in a single pass, preventing the material waste that would occur with repeated coating and stripping operations.
Solution Approach 2:
The system applies different active materials to specific local regions of the electrode in one continuous operation. The coating head is configured to deposit materials at predetermined locations along the substrate, ensuring that each material is applied only where needed without requiring global re-coating operations that would generate waste.
3Manufacturing precision
If multiple coating steps are used, then active material tailoring at higher resolution is achieved, but device complexity increases
Solution Approach 1:
The continuous coating process maintains high active material tailoring resolution by continuously monitoring and controlling material deposition rates and positions. The system uses a single coordinated motion system and coating head that can precisely control where different materials are deposited, achieving high-resolution tailoring without the complexity of multiple independent coating systems.
Solution Approach 2:
The coating system is designed as a multi-functional unit that can deposit different active materials in different regions during one continuous operation. Rather than requiring separate specialized coating equipment for each material layer, this universal coating head performs multiple functions - selecting, positioning, and depositing different materials - thereby reducing overall device complexity while maintaining high tailoring resolution.
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 approach reduces process time and material inefficiencies by integrating diverse layers and active materials efficiently, enhancing the performance and resolution of multi-layer coatings in lithium-ion batteries.
Implementation Method 1
heat roll pressed to form a second bilayer in which the wet coating-derived layer is at least partially dried
Implementation Method 2
adhered to the free-standing material layer
Data Source
AI summary
A method for forming one or more layers of a lithium-ion battery includes a step of sequentially depositing a wet coating and a free-standing material layer onto a moving substrate to form a first bilayer on the substrate. The first bilayer including a wet coating-derived layer and the free-standing material layer. The first bilayer is heat roll pressed to form a second bilayer in which the wet coating-derived layer is at least partially dried and adhered to the free-standing material layer.