Bilayer Electrode Crater Anchoring for Layer Detachment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The detachment of active material layers during the manufacturing process of electrodes for secondary batteries with a stacked configuration is a significant issue, particularly with the second layer detaching before pressing, which affects the integrity and productivity of the electrode.
Innovation Solution
The electrode design incorporates a first layer of active material with craters formed by laser ablation, which are filled with the second layer of active material, enhancing the anchor effect and interfacial adhesion, and the manufacturing method involves preparing and coating the first layer, forming craters, and then applying the second layer, allowing for improved binding and uniform reaction distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a stacked configuration of two active material layers is used to increase capacity and energy density, then the energy density and capacity are improved, but the active material layers detach during the conveying process
Solution Approach 1:
The patent applies preliminary action by forming craters in the first active material layer before coating the second layer. This pre-prepared surface structure with craters creates anchor points that prevent detachment during subsequent conveying and pressing operations, resolving the stability issue while maintaining the stacked configuration for high energy density.
Solution Approach 2:
The patent applies local quality by creating craters at specific locations on the surface of the first active material layer. These localized structural modifications provide enhanced adhesion points precisely where needed at the interface between layers, while the rest of the layer structure remains intact to maintain overall energy density.
2Ease of manufacture
If conventional coating and drying processes are used for stacked layers, then the manufacturing process is simple, but the second layer detaches before pressing
Solution Approach 1:
The crater formation step is introduced as a preliminary action between coating the first layer and coating the second layer. This intermediate step prepares the surface with anchor points that ensure reliable adhesion during subsequent handling and pressing, while the overall manufacturing process remains relatively simple and can be integrated into existing production lines.
3Ease of operation
If repeated conveying and winding processes are used during manufacturing, then storage and handling are convenient, but active material layers detach
Solution Approach 1:
By forming craters in advance before the conveying and winding operations, the patent creates strong bonding interfaces that can withstand the mechanical stresses of repeated handling, conveying, and winding operations. The anchor effect from craters prevents layer detachment even during convenient storage and handling operations.
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 prevents detachment of the active material layers, improves output characteristics, and enhances the uniformity of reaction distribution, while also increasing manufacturing productivity by enabling an in-line process.
Implementation Method 1
a plurality of craters are formed in the first layer of active material
Data Source
AI summary
Provided is an electrode for a secondary battery having an electrode current collector either surface or both surfaces of which are coated with two active material layers, the electrode including: an electrode current collector; a first layer of active material coated on the current collector; and a second layer of active material coated on the first layer of active material, wherein a plurality of craters are formed in the first layer of active material and the craters are filled with active material of the second layer. A method for manufacturing the electrode for a secondary battery is also provided, and the method includes carrying out laser ablation on the first layer of active material. According to the present disclosure, it is possible to solve the problem of detachment of the active material layers, particularly the second layer of active material, during the process for manufacturing the electrode.