Continuous Mixing System for Battery Electrode Coating
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Solution Overview
Problem
Existing methods for producing electrode coating materials for batteries, accumulators, and fuel cells are not suitable for large-scale production, as batch-wise mixing processes are inefficient and costly, and can damage sensitive active materials.
Innovation Solution
A continuous mixing process where the binder is first dissolved in liquid and then continuously conveyed, with other components being added sequentially or simultaneously, allowing for intensive mixing and homogeneity, using multiple mixing and dispersing devices to produce large quantities cost-effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch-wise mixing processes are used to produce electrode coating materials, then the mixing can be performed with simple equipment, but the production quantity is limited and the cost is high
Solution Approach 1:
The patent implements a continuous mixing process where the binder solution is continuously prepared and then continuously mixed with conductive material and active material through a series of mixing devices. This continuous operation eliminates the batch-wise stopping and starting, enabling large-scale production while maintaining mixing effectiveness through the sequential mixing stages.
Solution Approach 2:
The mixing process is divided into multiple sequential stages with separate mixing devices. First, the binder is dissolved in liquid to form a binder solution. Then, conductive material is mixed with the binder solution in a first mixing device. Finally, active material is mixed in a second mixing device. This segmentation allows each mixing stage to be optimized independently while enabling continuous operation for high productivity.
2Manufacturing precision
If multiple mixing operations are performed on active material, then the mixture homogeneity is improved, but the sensitive active material is damaged
Solution Approach 1:
The mixing process is segmented into distinct stages where conductive material is mixed with binder solution first in a first mixing device, and then active material is added and mixed in a second mixing device. This segmentation reduces the total number of mixing operations the sensitive active material undergoes, minimizing damage while still achieving homogeneity through the dedicated final mixing stage.
Solution Approach 2:
The conductive material is preliminarily mixed with the binder solution to form a pre-mixture before the active material is added. This preliminary action prepares the binding matrix in advance, so that when the sensitive active material is introduced, it only needs to be mixed once into the prepared pre-mixture, reducing repeated mixing exposure and associated damage.
3Productivity
If all components are mixed together in a single batch, then the process is simple, but the production scale is limited
Solution Approach 1:
The manufacturing process is segmented into continuous preparation of binder solution followed by sequential mixing with conductive material and active material through multiple mixing devices. This segmentation enables scalable continuous production while maintaining relatively simple individual mixing stages, allowing the process to be expanded in scale by increasing flow rates or adding parallel mixing lines without fundamentally changing the process complexity.
Solution Approach 2:
The process uses continuous preparation of binder solution that feeds continuously into the mixing devices, which in turn continuously mix with conductive and active materials. This continuous flow approach enables large-scale production by eliminating batch cycles, while the modular arrangement of mixing devices keeps the overall process structure relatively simple and易于 to scale.
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 enables the production of high-homogeneity electrode coating materials in large quantities at a lower cost, ensuring gentle treatment of sensitive active materials and efficient mixing processes.
Implementation Method 1
first the binder is continuously mixed with the liquid and dissolved in the liquid
Implementation Method 2
with a mixing device for mixing solid components with each other and with liquid
Data Source
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AI summary
The invention relates to a device (1) for producing a mixture for coating electrodes of batteries or accumulators or fuel cells, said mixture essentially consisting of a conductive material, an active material and at least one binder, as well as liquid with which the solid constituents are mixed. First, the binder is continuously mixed with the liquid and dissolved therein. The other constituents can be continuously successively and/or partially simultaneously mixed into the solution continuously formed in this way, and especially respectively dispersed, in order to continuously obtain an intensive homogeneous mixture. The device for producing such a mixture can be essentially a mixing system comprising at least two or, as required, three mixing devices (2, 3 and 14), the supply line (5) and the inlet (6) for the liquid being arranged upstream of the first mixing and dispersing device (2) in the transport direction, and the individual mixing devices are interconnected such that the mixing processes inside said devices and the subsequent transport of the respectively formed mixture from one mixing device to the next can be carried out continuously.