Dry-Coated Electrode Insulating Layer for Electrolyte Permeability
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Solution Overview
Problem
The high rate discharge performance of energy storage devices is compromised due to low electrolyte permeability when an insulating layer is formed on the surface of an active material layer using a wet coating technique.
Innovation Solution
An electrode with an insulating layer containing a filler and a binder, where the binder content is between 8% and 50% by mass, is formed using a dry coating process without solvents, ensuring the binder remains on the surface of the filler particles and maintains electrolyte permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating layer is formed on the surface of an active material layer using wet coating technique, then the insulating layer can be formed with binder and filler, but the electrolyte permeability decreases and high rate discharge performance deteriorates
Solution Approach 1:
The patent changes the coating method from wet coating to dry coating, eliminating the solvent component. This parameter change in the coating process maintains the insulating layer's structural stability while preventing solvent-related pore blockage, thereby preserving electrolyte permeability and high rate discharge performance
Solution Approach 2:
The patent utilizes a porous insulating layer structure formed through dry coating with filler particles. The porous structure allows electrolyte penetration while maintaining electrical insulation, resolving the contradiction between forming a stable insulating layer and maintaining electrolyte permeability
2Ease of manufacture
If wet coating technique is used to form insulating layer, then the coating process can proceed with paste application, but binder flows into active material layer causing performance degradation
Solution Approach 1:
The patent changes the physical state of the coating material from paste (wet) to powder (dry), eliminating the liquid phase that causes binder flow. This parameter change maintains manufacturing feasibility through dry coating while achieving precise binder distribution control by preventing binder migration into the active material layer
Solution Approach 2:
The patent extracts the solvent component from the coating material, transitioning from wet coating paste to dry coating powder. This extraction eliminates the medium that enables binder flow, thereby preventing manufacturing precision issues while maintaining ease of manufacture through simplified dry coating process
3Quantity of substance
If insulating layer is formed with low binder content, then electrolyte permeability is maintained, but the insulating layer peels from active material layer
Solution Approach 1:
The patent employs a composite insulating layer comprising filler particles and binder in specific proportions (8-50% by mass). This composite structure provides both adequate adhesion strength and sufficient porosity for electrolyte permeability, resolving the contradiction between layer strength and permeability
Solution Approach 2:
The patent optimizes the binder content parameter to a specific range (8-50% by mass) and changes the coating method to dry coating. These parameter changes ensure sufficient adhesion strength to prevent peeling while maintaining high electrolyte permeability through the porous structure
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 configuration enhances the high rate discharge performance of energy storage devices by maintaining electrolyte permeability and preventing binder flow into the active material layer, thereby stabilizing the insulating layer and preventing peeling.
Implementation Method 1
the insulating layer is obtained by a process of dry coating wherein no solvent is used and the coating is performed in a powder state
Implementation Method 2
the insulating layer contains a filler and a first binder
Implementation Method 3
the electrolyte permeability of this electrode is low
Data Source
Figure 1~2
Figure 3~4
AI summary
An aspect of the present invention is an electrode which includes an active material layer, and an insulating layer layered on a surface of the active material layer, in which the insulating layer contains a filler and a first binder, and a content of the first binder in the insulating layer is 8% by mass or more. Another aspect of the present invention is an electrode which includes an active material layer, and an insulating layer layered on a surface of the active material layer, in which the insulating layer is a dry coating product containing a filler and a binder. Still another aspect of the present invention is a method for manufacturing an electrode, which includes the steps of forming an active material layer, and laminating an insulator containing a filler and a binder on a surface of the active material layer to form an insulating layer, in which the insulator does not contain a solvent.