Dry Electrode Lamination With Attachment Layer for Stronger Adhesion
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Solution Overview
Problem
The existing methods for manufacturing electrodes for electrochemical devices, such as lithium secondary batteries, face challenges in achieving high adhesion strength between free-standing dry electrode films and current collectors, leading to potential separation during assembly.
Innovation Solution
A method involving the formation of an attachment enhancing layer on the current collector using a slurry with a binder polymer and conductive material, followed by stacking the free-standing dry electrode film and applying heat and pressure to allow the binder polymer to permeate into the surface layer, enhancing adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a free-standing dry electrode film is laminated with the current collector to manufacture an electrode, then the manufacturing process avoids solvent use (environmental benefit), but the adhesion strength between the dry electrode film and current collector becomes weak causing separation during assembly
Solution Approach 1:
An attachment enhancing layer is pre-formed on the current collector surface before the dry electrode film is applied. This preliminary action creates a surface treatment that promotes strong adhesion between the current collector and the subsequently applied dry electrode film, preventing separation during assembly while maintaining the solvent-free manufacturing advantage
Solution Approach 2:
The attachment enhancing layer acts as an intermediary substance between the current collector and the dry electrode film. This intermediate layer facilitates strong bonding by providing a surface that the dry electrode film can adhere to, while the layer itself is firmly attached to the current collector, thus resolving the adhesion strength problem without compromising the dry manufacturing process
2Strength
If the adhesion strength between dry electrode film and current collector is increased through stronger bonding methods, then separation is prevented, but the interfacial resistance increases reducing electrochemical performance
Solution Approach 1:
The attachment enhancing layer provides localized adhesion promotion at the interface between the current collector and dry electrode film, while maintaining appropriate electrical conductivity properties. Different regions of the interface have optimized properties: strong mechanical bonding in some areas and good electrical contact in others, thus achieving both high adhesion strength and low interfacial resistance simultaneously
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 significantly increases the adhesion strength between the dry electrode film and the current collector, while maintaining suitable interfacial resistance, thereby improving the stability and performance of the electrode.
Implementation Method 1
applying heat and pressure in order to allow the binder polymer to permeate into a surface layer of the free-standing dry electrode film
Implementation Method 2
adhere the free-standing dry electrode film to the attachment enhancing layer
Implementation Method 3
applying heat and pressure
Implementation Method 4
applying heat and pressure
Data Source
AI summary
Provided is a method for manufacturing an electrode for an electrochemical device comprising (S1) coating a slurry comprising a binder polymer and a conductive material on at least one surface of a current collector and drying to form an attachment enhancing layer; (S2) preparing a free-standing dry electrode film comprising a dry electrode active material and a dry binder; and (S3) stacking the free-standing dry electrode film on the attachment enhancing layer and applying heat and pressure in order to allow the binder polymer to permeate into a surface layer of the free-standing dry electrode film in contact with the attachment enhancing layer in order to adhere the free-standing dry electrode film to the attachment enhancing layer. Further provided are an electrode and a lithium secondary battery including the same.