Composite Particle Electrode Manufacturing via Spray-Drying
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Solution Overview
Problem
Existing methods for manufacturing electrochemical device electrodes face challenges in achieving high thickness precision at low basis weight, often resulting in hopper troubles and inconsistent electrode thickness due to the properties of composite particles used in pressure molding processes.
Innovation Solution
The development of composite particles with reduced fine powder content, where particles of 40 µm or less constitute 50% or less of the number-based particle size distribution and a cumulative 95% size of 300 µm or less in volume-based distribution, optimized through spray-drying and classification, enables precise feeding and molding of electrodes with improved fluidity and reduced basis weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If composite particles with high fine powder content are used in pressure molding, then the electrode active material layer can be formed, but hopper troubles occur and thickness precision deteriorates
Solution Approach 1:
The patent changes the particle size distribution parameters of composite particles by controlling the ratio of fine powder to total particles. Specifically, it sets the fine powder content (particles of 40 µm or less) to 60% or less by number-based particle size distribution, which optimizes both flowability for hopper operation and thickness precision for electrode manufacturing.
2Weight of moving object
If the basis weight of composite particles is reduced to achieve low basis weight electrode, then electrode weight is lowered, but stable feeding of constant amount becomes difficult
Solution Approach 1:
The patent optimizes particle size distribution parameters to improve flowability and feeding stability. By controlling the fine powder content to 60% or less by number-based distribution and setting specific D10, D50, and D90 values, the composite particles achieve reliable constant amount feeding even at low basis weight, preventing hopper troubles while maintaining low electrode weight.
3Manufacturing precision
If conventional slurry application method is used, then electrode active material layer can be formed, but binder resin migration occurs and uniformity is poor
Solution Approach 1:
The patent replaces the conventional slurry application method (which involves liquid application and drying) with a dry pressure molding method using composite particles. This substitution eliminates binder resin migration issues and achieves uniform electrode active material layers through controlled compression of dry particles, simplifying the manufacturing process while improving uniformity.
4Quantity of substance
If fine powder content is increased to improve electrode density, then capacity increases, but hopper troubles and processing difficulty increase
Solution Approach 1:
The patent optimizes the particle size distribution parameters to achieve the right balance between density and processability. By setting fine powder content to 60% or less by number-based distribution while controlling D10, D50, and D90 values, the composite particles achieve sufficient electrode density for high capacity while maintaining excellent flowability and processing ease without hopper troubles.
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 allows for the production of electrodes with high thickness precision and low basis weight, preventing hopper troubles and ensuring uniformity and efficiency in the manufacturing process.
Implementation Method 1
spray-drying a slurry containing an electrode active material and a binder resin
Implementation Method 2
spray-drying a slurry containing an electrode active material and a binder resin
Data Source
Figure 1
AI summary
An object of the present invention is to provide composite particles for an electrochemical device electrode capable of preparing an electrode having high thickness precision at a low basis weight, an electrochemical device electrode and an electrochemical device that use the composite particles for an electrochemical device electrode, and to provide a method for manufacturing the composite particles for an electrochemical device electrode, and a method for manufacturing the electrochemical device electrode. The present invention relates to composite particles for an electrochemical device electrode that are obtained by spray-drying a slurry containing an electrode active material and a binder resin, in which particles of 40 µm or less are 50% or less of an entire amount in a number-based particle size distribution obtained by particle size measurement using a laser light diffraction method and the cumulative 95% size (D95 size) is 300 µm or less in a volume-based particle size distribution.