Battery Manufacturing via Binder Merging and Rolling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery manufacturing methods, such as those involving adhesive resin layers, increase the number of process steps, thickness of the separator, and resistance, leading to reduced productivity and battery performance.
Innovation Solution
A method that includes granulation, deposition, rolling, and drying steps to form a laminated body with a current collector, active material layer, and separator, omitting the adhesive resin layer and using a binder to enhance adhesion and density, thereby reducing resistance and improving battery performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an adhesive resin layer is formed on the separator surface, then adhesion between electrodes and separator is improved, but the number of process steps increases significantly
Solution Approach 1:
The binder material is incorporated into the active material layer itself, merging the functions of active material deposition and adhesion promotion into a single layer. This eliminates the need for a separate adhesive resin layer on the separator, reducing process steps while maintaining adhesion through the binder-containing active material layer that contacts the separator directly.
2Strength
If an adhesive resin layer is added to the separator, then adhesion is enhanced, but the separator thickness increases
Solution Approach 1:
The adhesive function is merged into the active material layer through the binder, eliminating the need for an additional adhesive resin layer on the separator. This keeps the separator thickness minimal while achieving adhesion through the binder-containing active material that directly contacts the separator surface.
3Reliability
If an adhesive resin layer is used, then electrode-separator integration is improved, but battery resistance increases
Solution Approach 1:
The adhesive resin layer is replaced by incorporating binder material directly into the active material layer. This eliminates the additional interface and material layer that would increase resistance, while maintaining reliable electrode-separator integration through the binder-containing active material that is in direct contact with the separator.
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 method reduces the number of process steps, minimizes separator thickness, and enhances battery performance by improving adhesion and density, resulting in more efficient battery manufacturing with lower resistance.
Implementation Method 1
closely attached to each other
Implementation Method 2
a drying step of drying the laminated body to provide an integrated laminated body
Data Source
AI summary
The present invention provides a method for manufacturing a battery which includes a granulation step (Step S1) of mixing at least an active material, a binder, and a solvent to form wet granulated particles, a deposition step (Step S2) of subjecting the wet granulated particles to a forming process to form an active material layer on a current collector, a rolling step (Step S3) of placing a separator on a surface of the active material layer and rolling the separator before the wet granulated particles on the current collector are dried, to obtain a laminated body in which the current collector, the active material layer, and the separator are stacked in this order and closely attached to each other, a drying step (Step S4) of drying the laminated body to provide an integrated laminated body, and a fabrication step (Step S5) of fabricating a battery using the integrated laminated body.