Dry-Processed Secondary Battery Electrodes With Uniform Binder Distribution

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Solution Overview

Problem

Conventional secondary battery manufacturing processes result in uneven material distribution and surface defects due to solvent evaporation and migration, leading to decreased adhesion and lifespan characteristics.

Innovation Solution

A secondary battery design utilizing dry electrode preparation methods for both positive and negative electrodes, incorporating a fiberized binder for the positive electrode and granules for the negative electrode, eliminating the need for solvent drying processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a drying process is used to remove solvent from electrode slurry, then the electrode can be formed, but uneven material distribution and surface defects occur due to solvent evaporation and migration

Engineering Contradiction:

Improveelectrode formation processVSAvoidmaterial distribution uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention extracts and eliminates the drying process from the electrode manufacturing workflow. By using a water-soluble binder that dissolves in water, the slurry can be directly applied and the water naturally evaporates or is removed without causing the harmful effects of conventional drying processes, thus removing the source of the problem while maintaining the necessary function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention changes the key parameter of binder solubility from organic-soluble to water-soluble. This parameter change allows the use of water as the slurry solvent instead of organic solvents, fundamentally altering the evaporation characteristics and eliminating the material migration issues associated with conventional drying processes while maintaining electrode formation capability.

Inventive Principle:

Principle #35Parameter changes

2Loss of substance

If conventional drying process is used, then solvent is removed, but binder migration to electrode surface occurs causing decreased adhesion

Engineering Contradiction:

Improvesolvent removalVSAvoidadhesion to current collector

Core Design Contradiction:

Loss of substanceVSStrength

Solution Approach 1:

The invention changes the binder's chemical parameter from organic-soluble to water-soluble, which fundamentally alters its behavior during solvent removal. Water-soluble binders like carboxymethyl cellulose maintain their binding properties through hydrogen bonding and gel formation rather than organic solvent interactions, preventing the migration and adhesion loss problems experienced with conventional binders during drying.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses water as a temporary, disposable solvent that naturally evaporates or can be easily removed without leaving harmful residues. Water serves its purpose of enabling slurry application and then disappears without causing the persistent binder migration and adhesion degradation problems associated with organic solvents and their evaporation processes.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Power

If rapid charging is implemented, then power delivery improves, but lifespan characteristics deteriorate

Engineering Contradiction:

Improvecharging rateVSAvoidbattery lifespan

Core Design Contradiction:

PowerVSDuration of action of stationary object

Solution Approach 1:

The invention applies local quality improvement by ensuring uniform distribution of active material, conductive material, and binder throughout the electrode matrix. This uniformity, achieved through the water-soluble binder system, creates consistent local environments for electrochemical reactions, preventing localized stress concentrations and degradation that would otherwise limit lifespan during rapid charging operations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of accepting that rapid charging inherently causes lifespan degradation through conventional electrode structures, the invention inverts the approach by designing an electrode architecture where the water-soluble binder creates a more flexible and uniform matrix that can accommodate rapid charging stresses, thereby enabling high power delivery without the typical lifespan penalty.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS12580197B2Secondary battery

Publication Date: 2026.03.17 LG ENERGY SOLUTION LTD

AI summary

Provided is a secondary battery including: a positive electrode including a positive electrode current collector and a positive electrode active material layer located on the positive electrode current collector and including a positive electrode active material, a positive electrode conductive material and a positive electrode binder, wherein the positive electrode binder is fiberized and binds the positive electrode active material and the positive electrode conductive material; a negative electrode including a negative electrode current collector and a negative electrode active material layer located on the negative electrode current collector and including a plurality of granules including a negative electrode active material and a negative electrode binder, and formed as the negative electrode binder binds the negative electrode active material; and a separator disposed between the positive electrode and the negative electrode.