Battery Electrode Lamination with Pyrolyzed Adhesive for Stronger Anodes
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Solution Overview
Problem
Conventional battery anode manufacturing methods are costly, cumbersome, and inefficient, leading to limitations in battery lifetime due to issues like poor adhesion between active material layers and current collectors, which result in capacity loss and reduced cycle life.
Innovation Solution
A continuous lamination method is employed where a polymer adhesive layer is applied to a current collector film, followed by an active material layer, and then heat-treated to induce pyrolysis, ensuring more carbonization in the active material layer than the adhesive layer, enhancing adhesion and flexibility, and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional battery anode manufacturing methods are used, then production can be achieved, but the process is costly, cumbersome, and inefficient with poor adhesion between active material layers and current collectors
Solution Approach 1:
A polymer adhesive layer is introduced as an intermediary between the current collector and the active material layer. This adhesive layer improves adhesion quality while enabling continuous lamination manufacturing, thus resolving the contradiction between manufacturing efficiency and adhesion quality.
Solution Approach 2:
The anode structure is designed as a composite material system consisting of the current collector, polymer adhesive layer, and active material layer. This composite structure achieves both strong adhesion and compatibility with continuous manufacturing processes.
2Productivity
If conventional manufacturing methods are used, then production can be achieved, but battery lifetime is limited due to capacity loss and reduced cycle life
Solution Approach 1:
The polymer adhesive layer serves as a mediator that ensures strong bonding between layers, preventing delamination during battery cycling. This improves battery lifetime and cycle life while maintaining continuous production capability.
Solution Approach 2:
The patent applies heat treatment to induce pyrolysis of the polymer adhesive, transforming it into a carbon-rich adhesive layer. This parameter change (thermal treatment) enhances adhesion strength and structural stability, improving battery durability while maintaining manufacturing productivity.
3Strength
If heat treatment is applied to induce pyrolysis, then adhesion and flexibility are enhanced, but additional process steps are required
Solution Approach 1:
The heat treatment step for pyrolysis is combined with the existing drying process in continuous lamination. By merging the thermal processing steps, the patent achieves enhanced adhesion strength without significantly increasing process complexity.
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 results in a more robust, flexible anode with improved adhesion, allowing for higher-speed, continuous production, reducing capacity loss, and enhancing the cycle life of lithium-ion batteries.
Implementation Method 1
heat-treated to induce pyrolysis, ensuring more carbonization in the active material layer than the adhesive layer
Data Source
AI summary
Systems and methods for continuous lamination of battery electrodes may include a cathode, an electrolyte, and an anode, where the anode includes a current collector, a cathode, an electrolyte, and an anode, the anode comprising a polymeric adhesive layer coated onto the current collector, and an active material coated onto the polymeric adhesive layer such that the polymeric adhesive layer is arranged between the active material and the current collector, wherein the anode is subjected to a heat treatment to induce pyrolysis after application of the polymeric adhesive layer to the current collector and application of the active material to the polymeric adhesive layer, the heat being applied to the anode at a temperature between 500 and 850 degrees C.