Composite Delamination Solution for Clean Electrode Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for delaminating composites with aqueous polymeric binders are inefficient, time-consuming, and often result in incomplete separation, leading to undesirable recovery losses and contamination of metal substrates, especially when the binders exhibit strong adhesion to the substrate.
Innovation Solution
A method involving immersion of the composite in a delamination solution containing a delamination agent and an aqueous solvent, which disrupts the hydrogen and ion-dipole interactions between the polymeric binder and the metal substrate by using a copolymer with structural units derived from acid and nitrile group-containing monomers, facilitating rapid and complete delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional delamination methods are used, then delamination can be achieved, but the process is highly inefficient and time-consuming (taking up to several hours)
Solution Approach 1:
The patent changes the chemical parameters of the delamination solution by specifying precise compositions including water, organic solvents (acetone, ethanol, isopropanol), and chelating agents (EDTA, citric acid) at controlled concentrations. This optimized parameter combination enables rapid delamination within minutes rather than hours, directly improving productivity while reducing time loss
Solution Approach 2:
The patent introduces chelating agents (EDTA, citric acid) as intermediary substances that mediate between the delamination solution and the coating-metal substrate interface. These intermediaries disrupt the bonding interactions efficiently, enabling rapid delamination without requiring prolonged exposure times, thus resolving the contradiction between efficiency and time consumption
2Productivity
If drastic delamination conditions are applied for sustained periods, then delamination can be achieved, but side effects such as corrosion, dissolution and damage of composite constituents occur
Solution Approach 1:
The patent optimizes the parameters of the delamination solution by using mild concentrations of organic solvents (5-50% v/v) and chelating agents (0.1-5% w/v), maintaining pH between 2-7. This controlled parameter regime achieves complete delamination without causing corrosion or damage to the metal substrate and coating constituents, eliminating harmful side effects while maintaining productivity
Solution Approach 2:
The patent employs a disposable delamination solution formulation that achieves complete delamination in minutes without requiring prolonged drastic conditions. The solution is designed to be used once and discarded after achieving the delamination objective, avoiding the accumulation of harmful effects on the composite constituents while maintaining high productivity
3Stability of the object's composition
If aqueous polymeric binders are used in water-based coating, then superior dispersion and stability are achieved, but strong coating-metal substrate adhesion poses additional challenge in delamination
Solution Approach 1:
The patent introduces chelating agents (EDTA, citric acid) and organic solvents as intermediary substances that specifically target and disrupt the bonding between the aqueous polymeric binder and the metal substrate. These intermediaries penetrate the coating layer and break the adhesion bonds without affecting the dispersion and stability properties of the aqueous binder during coating application, thus resolving the contradiction between stability and adhesion strength
Solution Approach 2:
The patent changes the chemical environment parameters during delamination by using specific pH ranges (2-7) and solvent compositions that selectively weaken the adhesion bonds formed by aqueous polymeric binders. This parameter optimization allows the coating to maintain its superior dispersion and stability during application while enabling easy delamination when needed, resolving the contradiction between these two properties
4Productivity
If delamination occurs within the bulk layer rather than at the interface, then separation takes place, but coating materials are lost and metal substrate contains high levels of impurities
Solution Approach 1:
The patent employs chelating agents (EDTA, citric acid) and organic solvents as intermediaries that specifically target the coating-metal substrate interface. These intermediaries preferentially interact with and disrupt the bonding at the interface rather than within the bulk coating layer, ensuring precise delamination at the desired location. This prevents coating material loss and avoids contaminating the metal substrate, resolving the contradiction between achieving separation and maintaining precision
Solution Approach 2:
The patent optimizes the chemical parameters of the delamination solution (pH 2-7, specific solvent and chelating agent concentrations) to selectively affect the interface bonding strength without impacting the bulk coating structure. This parameter control ensures that delamination occurs precisely at the coating-metal substrate interface, achieving complete separation while maintaining manufacturing precision and avoiding material loss or substrate contamination
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
The method achieves rapid and complete delamination of the coating from the metal substrate, reducing recovery losses and contamination, while utilizing environmentally friendly solvents, thus enhancing materials recovery efficiency.
Implementation Method 1
the delamination solution comprises a delamination agent and an aqueous solvent... which disrupts the hydrogen and ion-dipole interactions between the polymeric binder and the metal substrate
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
Provided is a method for delaminating a composite by immersing the composite into a delamination solution; wherein the composite comprises a substrate and a coating applied on one side or both sides of the substrate comprising a polymeric binder; and wherein the polymeric binder comprises a copolymer comprising a structural unit derived from an acid group-containing monomer. The use of weak acid-containing delamination solution allows for complete delamination of the composite in a highly efficient manner. Furthermore, the delamination method disclosed herein circumvents complex separation process, contamination and corrosion of substrate and enables an excellent materials recovery. An application of the method for delaminating an electrode for a battery is also disclosed.