Composite Electrode Particles for Uniform Electrostatic Coating
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Solution Overview
Problem
Existing methods for manufacturing electrodes for electrochemical energy storage devices, such as lithium-ion batteries, face challenges in achieving high transfer efficiency and uniformity in solvent-free electrostatic deposition due to the use of ultra-fine active particles, which result in low chargeability and poor flowability, leading to non-uniform coating layers and reduced battery performance.
Innovation Solution
The method involves forming agglomerates from ultra-fine active particles with binders to create composite particles, which are then deposited using electrostatic deposition, ensuring high transfer efficiency and uniformity by maintaining the defined stoichiometry and mechanical stability of the coating layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If ultra-fine active particles are used in electrostatic deposition, then the energy density and performance of the electrode are improved, but the transfer efficiency and uniformity of the coating layer deteriorate due to low chargeability and poor flowability
Solution Approach 1:
The patent introduces binder materials as intermediaries that coat the ultra-fine active particles, forming composite particles with improved chargeability and flowability. The binder acts as a mediator between the ultra-fine particles and the electrostatic deposition process, enabling uniform coating while preserving the high energy density benefits of the fine particles.
Solution Approach 2:
The patent creates composite particles by combining ultra-fine active particles with binder materials. This composite structure maintains the high surface area and energy density of the ultra-fine particles while the binder provides the necessary chargeability and flowability for uniform electrostatic deposition.
2Reliability
If ultra-fine active particles are used, then the electrochemical performance is enhanced, but the chargeability and flowability decrease leading to non-uniform deposition
Solution Approach 1:
The binder material serves as an intermediary that improves the chargeability of ultra-fine particles. By coating the particles with binder, the system achieves both high electrochemical performance from the fine particles and adequate chargeability for electrostatic deposition through the binder's properties.
Solution Approach 2:
The patent modifies the particle properties by changing the composition and surface characteristics through binder coating. This parameter change in the particle structure enables ultra-fine particles to achieve sufficient chargeability and flowability while maintaining their electrochemical performance.
3Loss of energy
If solvent-free electrostatic deposition is used, then the manufacturing cost and energy consumption are reduced, but the transfer efficiency and coating uniformity are compromised
Solution Approach 1:
The patent uses composite particles consisting of active material and binder to achieve high transfer efficiency in solvent-free electrostatic deposition. The composite structure enables the particles to be properly charged and deposited uniformly without requiring energy-intensive solvent removal processes.
Solution Approach 2:
The patent optimizes particle properties through binder incorporation, changing parameters such as surface charge characteristics and flowability. This enables solvent-free deposition to achieve high transfer efficiency and coating uniformity that were previously only attainable with solvent-based methods.
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 enhances the transfer efficiency and uniformity of the coating layer, preserving the beneficial properties of ultra-fine particles, thereby improving the performance and efficiency of the electrodes in batteries.
Implementation Method 1
electrostatically charging the fluidized powder particles, and allowing the charged particles to flow and travel in an electric field, such that the charged particles reach and deposit onto a grounded electrically conductive substrate
Implementation Method 2
allowing the charged particles to flow and travel in an electric field
Implementation Method 3
heating and compressing the coated current collector to form an electrode
Data Source
AI summary
An exemplary method of fabricating an electrode for electrochemical energy storage devices is provided. The method includes forming agglomerates from ultra-fine active particles that include one or more binder I materials. The method includes forming composite particles by combining the agglomerates with one or more binder II materials. The method includes depositing the composite particles onto an electrically conductive substrate through an electrostatic deposition process to form a coating layer. The method includes densifying the coating layer and the electrically conductive substrate to form an electrode.