Rechargeable Battery Electrode Mixed Layer Binder Distribution
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Solution Overview
Problem
The existing methods for forming electrode active material layers in rechargeable batteries result in variations in binder distribution, leading to reduced binding strength due to the mixing of composite and insulation pastes at the interface, causing the composite layer to dry quickly and thin out, especially at the edges.
Innovation Solution
A method involving a composite layer and an insulation layer where the insulation layer covers the substrate surface, forming a mixed layer with a higher binder content ratio than the composite paste, and the composite paste is applied in greater amounts than the insulation paste, ensuring the composite layer maintains sufficient thickness and binding strength by preventing the insulation layer from extending beyond the composite slope's formation range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the composite paste and insulation paste are simultaneously applied to the substrate, then the production efficiency is improved, but the binder distribution uniformity deteriorates due to mixing at the interface region
Solution Approach 1:
The patent divides the interface region into two separate zones: a first region where only composite paste is applied and a second region where only insulation paste is applied. This segmentation prevents mixing of the two pastes while maintaining simultaneous application processes, thereby preserving binder distribution uniformity without sacrificing production efficiency.
2Reliability
If the composite layer thickness is reduced at the edge for insulation coverage, then the insulation effectiveness is improved, but the binding strength deteriorates due to quick drying and binder variation
Solution Approach 1:
The patent applies different paste types to different local regions: composite paste is applied to the first region (electrode active material area) while insulation paste is applied to the second region (insulation area). This local differentiation ensures that each region receives the appropriate material properties - binding strength where needed and insulation where required - without compromising either function.
3Reliability
If the insulation layer extends beyond the composite slope formation range, then the insulation coverage is improved, but the composite layer thickness and binding strength are reduced
Solution Approach 1:
The patent clearly segments the substrate into a first region for composite paste application and a second region for insulation paste application. The insulation layer is confined to the second region and does not extend into the first region, ensuring that the composite layer maintains its full thickness and binding strength in the electrode active material area while still providing adequate insulation coverage in the second region.
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 enhances the binding strength of the composite layer, particularly at the interface and distal end portions, thereby improving the performance and stability of the rechargeable battery by maintaining the composite layer's thickness and preventing corrosion.
Implementation Method 1
A mixed layer is formed between the insulation layer and the composite layer when the composite paste and the insulation paste mix in an overlapping range
Implementation Method 2
The composite paste is dried to form a composite layer that serves as an electrode active material layer
Data Source
AI summary
An electrode body includes a substrate serving as a collector, a composite layer formed by applying a composite paste including an electrode active material to the substrate, and an insulation layer formed by applying an insulation paste including an insulative material to the substrate adjacent to the composite layer. The composite layer extends above and overlaps the insulation layer that covers a surface of the substrate in an interface region of the composite layer and the insulation layer. A mixed layer is formed between the insulation layer and the composite layer when the composite paste and the insulation paste mix in an overlapping range of the insulation layer and the composite layer. The mixed layer is formed in a range where the insulation layer covers the surface of the substrate.