Battery Separator Formation via Undried Layer Coating
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Solution Overview
Problem
The existing method for forming a separator layer on an electrode plate for batteries is complex, inefficient, and prone to forming voids and through-holes, making it difficult to achieve uniformity and high productivity.
Innovation Solution
A production method involving an undried active material layer and an undried separator layer formed using a polymer solution with a water-soluble polymer and a high-boiling point solvent, where the water-soluble polymer is deposited in a three-dimensional network, and the dispersion medium is vaporized to prevent voids and through-holes, ensuring a uniform separator layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the polymer solution is applied onto a dried active material layer to form the undried separator layer, then the separator layer can be formed, but voids and through-holes are formed in the separator layer, resulting in non-uniform formation
Solution Approach 1:
The active material layer is formed in an undried state before applying the polymer solution, so that the dispersion medium fills the voids of the active material particles. This preliminary action prevents air from being trapped when the separator layer is formed, eliminating voids and through-holes in the final separator layer.
2Manufacturing precision
If the existing method using water-soluble polymer is employed to form separator layer, then separator layer can be formed, but the process is complicated and productivity is poor
Solution Approach 1:
The formation of the active material layer and separator layer is merged into a single continuous process without intermediate drying steps. The polymer solution is applied onto the undried active material layer, and both layers are dried together in one drying step, significantly simplifying the process and improving productivity.
Solution Approach 2:
The process maintains continuity by avoiding interruption for drying the active material layer between formation of the active material layer and separator layer. The polymer solution is applied while the active material layer is still wet, and drying continues without interruption, ensuring continuous production flow.
3Manufacturing precision
If the existing method is used to form separator layer on electrode plate, then separator layer can be formed, but the method is difficult to apply to electrode plate production
Solution Approach 1:
The method is designed to be universally applicable to electrode plate production by forming both the active material layer and separator layer in an integrated process. The use of water-soluble polymer and high-boiling point solvent combination allows the same process to be used for various electrode plate configurations and active materials.
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 allows for the uniform formation of a separator layer on the active material layer, enhancing the reliability and efficiency of battery production by preventing voids and through-holes, thus improving the overall battery performance.
Implementation Method 1
water is vaporized from the undried separator layer to deposit the water-soluble polymer in the shape of a three-dimensional network
Implementation Method 2
the high-boiling point solvent is vaporized therefrom to obtain a porous separator layer
Implementation Method 3
forming the active material layer by vaporizing the dispersion medium contained in the undried active material layer
Data Source
AI summary
A production method for a separator-including electrode plate includes a step of forming an undried active material layer on a current collector foil, a step of forming an undried separator layer on the undried active material layer by applying a polymer solution containing a water-soluble polymer, water and a high-boiling point solvent, and a step of forming the porous separator layer by vaporizing the high-boiling point solvent after depositing the water-soluble polymer in the shape of a three-dimensional network by vaporizing the water contained in the undried separator layer, and forming the active material layer by vaporizing the dispersion medium contained in the undried active material layer.