Bipolar Electrode Laminate Pressing for Dual-Layer Density Control
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Solution Overview
Problem
In bipolar battery manufacturing, achieving desired densities for both positive and negative electrode active material layers is challenging due to differences in material flexibility, leading to uneven compression and increased manufacturing processes.
Innovation Solution
A method involving forming a positive electrode active material layer and a negative electrode active material layer on separate current collector layers, pressing them together, and dissolving the electrolyte component in the negative electrode layer with a solvent to prevent densification and create an electrolytic solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a positive electrode active material layer precursor and a negative electrode active material layer precursor are dried and pressed simultaneously, then the manufacturing process is simplified, but the softer layer is preferentially compressed resulting in undesired density distribution
Solution Approach 1:
The patent applies different properties to different layers by incorporating an electrolyte component specifically into the negative electrode active material layer precursor. This creates a local difference in compressibility between the two layers during pressing, allowing the positive electrode layer to be compressed to high density while the negative electrode layer maintains lower density due to the electrolyte component acting as a cushioning agent.
Solution Approach 2:
The electrolyte component serves as an intermediary substance within the negative electrode layer that mediates the compression process. During pressing, the electrolyte component temporarily increases the flexibility and compressibility of the negative electrode layer, preventing preferential compression and allowing controlled density distribution in both layers simultaneously.
2Manufacturing precision
If separate pressing steps are used for positive and negative electrode layers, then desired density can be achieved in each layer, but the number of manufacturing processes increases
Solution Approach 1:
The patent merges the pressing operations for both positive and negative electrode layers into a single simultaneous pressing step. By incorporating the electrolyte component into the negative electrode layer precursor, the patent enables both layers to be pressed together while achieving different density levels, thus combining multiple operations into one without sacrificing density control.
Solution Approach 2:
The patent changes the physical-chemical parameters of the negative electrode layer by adding an electrolyte component, which alters its compressibility characteristics. This parameter change allows the negative electrode layer to respond differently to pressing forces compared to the positive electrode layer, enabling simultaneous pressing with differentiated density outcomes.
3Adaptability or versatility
If the negative electrode active material layer is made with low to medium density to absorb expansion and contraction, then flexibility is improved, but high capacity is reduced
Solution Approach 1:
The patent applies different density requirements to different electrode layers locally. The negative electrode layer is designed with lower density to accommodate expansion and contraction, while the positive electrode layer achieves high density for high capacity. This local differentiation allows each layer to optimize its properties independently.
Solution Approach 2:
The electrolyte component acts as a mediator that enables the negative electrode layer to maintain lower density without compromising overall battery performance. It provides the necessary flexibility and ion conductivity while allowing the layer to absorb volume changes during charge-discharge cycles.
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 achieving desired densities in both electrode layers with a reduced number of manufacturing steps and utilizing the electrolytic solution within the battery, enhancing the manufacturing efficiency of bipolar electrodes and batteries.
Implementation Method 1
dissolving the electrolyte component in the second electrode active material layer with a solvent to produce an electrolytic solution after pressing
Data Source
AI summary
The present disclosure provides a method for manufacturing a bipolar electrode laminate in which a positive electrode active material layer and a negative electrode active material layer can each have a desired density and a small manufacturing process. The method of the present disclosure for manufacturing a bipolar electrode laminate comprising, providing a first electrode mixture, and the second electrode mixture comprising an electrolyte component, forming the first electrode mixture on a first surface of a current collector layer to form a first electrode active material layer precursor, and forming the second electrode mixture on a second surface of the current collector layer to form a second electrode active material layer precursor, pressing a laminate comprising the first electrode active material layer precursor, the current collector layer, and the second electrode active material layer precursor, and dissolving the electrolyte component with a solvent to produce an electrolytic solution.