Battery Electrode Solvent Level for Substrate Peeling
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Solution Overview
Problem
Conventional battery anode production methods are costly, cumbersome, and inefficient, limiting battery lifetime due to complex and time-consuming processes, and issues with peeling the active material from substrates during production.
Innovation Solution
A method and system where the solvent level in the electrode active material is selected to facilitate peeling of the substrate during production, with a residual solvent range of approximately 10% to 25% by weight, allowing for efficient separation and subsequent lamination onto a current collector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional battery anode production methods are used, then the active material can be formed on a substrate, but the peeling process becomes complex and time-consuming
Solution Approach 1:
The patent changes the chemical composition parameters of the slurry by incorporating specific solvents (NMP, DMF, DMSO, or water) at controlled concentrations. This parameter modification enables the active material layer to be peeled from the substrate through solvent-mediated debonding, transforming a mechanically complex peeling process into a chemically facilitated separation that significantly improves productivity while reducing process complexity
Solution Approach 2:
The patent introduces solvent molecules as intermediary substances between the active material and substrate. These solvents penetrate the interface and facilitate separation by reducing adhesion forces, acting as a mediating agent that enables easy peeling without requiring complex mechanical or thermal processes, thus resolving the contradiction between production efficiency and process complexity
2Loss of time
If the peeling process is simplified, then production time is reduced, but incomplete removal may leave residue affecting battery performance
Solution Approach 1:
The solvent acts as an intermediary that uniformly penetrates the interface between active material and substrate, ensuring complete and uniform debonding across the entire surface. This mediator approach guarantees reliable peeling without residue while maintaining fast processing speed, resolving the contradiction between time loss and peeling completeness
Solution Approach 2:
The patent replaces mechanical peeling methods with a chemical substitution approach where solvent molecules displace the adhesive bonds between active material and substrate. This substitution enables complete removal through chemical interaction rather than forceful mechanical separation, ensuring no residue remains while reducing the time and complexity of the peeling operation
3Ease of manufacture
If conventional slurry composition is used, then the active material can be coated on substrate, but peeling becomes difficult and costly
Solution Approach 1:
The patent modifies the slurry composition parameters by incorporating specific solvents at optimized concentrations. This chemical parameter change transforms the adhesion characteristics, enabling easy peeling through solvent-mediated debonding while maintaining cost-effectiveness, thus resolving the contradiction between manufacturing ease and material loss costs
Solution Approach 2:
The patent employs inexpensive solvent molecules as temporary, disposable intermediaries that facilitate peeling and are subsequently removed or evaporated. These cheap solvent substances enable easy manufacturing through simple peeling processes without requiring expensive specialized equipment or materials, resolving the contradiction between ease of manufacture and production costs
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 simplifies the production process, improves peeling efficiency, and enhances the reliability and energy density of lithium-ion batteries by ensuring complete and uniform removal of the anode from the substrate, reducing residue and maintaining electrical contact during charge and discharge cycles.
Implementation Method 1
a residual amount of solvent in the electrode active material is selected to facilitate peeling of a substrate from the active material that is later attached onto the current collector
Data Source
AI summary
Systems and methods for a battery electrode having a solvent level to facilitate peeling are disclosed. In examples, a battery may include one or more electrodes and an electrolyte. The electrodes include an electrode slurry layer with a solvent. The electrode slurry is coated on a substrate, where the electrode slurry and substrate produce an active material with a residual amount of solvent in response to a heat-treatment, and where the active material comprises 10% to 25% residual solvent by weight following the heat-treatment. The amount of residual solvent facilitates peeling of the active material from the substrate, which, once pyrolyzed, may be used to create a multi-layer film with the current collector film and the active material.