Dry Electrode Powder Processing to Preserve Binder Fibrils
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Solution Overview
Problem
Existing methods for manufacturing dry electrodes for secondary batteries face issues such as solvent-induced defects, non-uniform drying, and high-shear mixing leading to micronization of active materials and cutting of binder fibers, which degrade mechanical and electrochemical performance, and are not amenable to mass production.
Innovation Solution
A low-shear kneading and pulverization process is used to prepare a powder for the dry electrode, minimizing active material micronization and maximizing binder fibrilization, resulting in a flexible and high-performing dry electrode suitable for mass production without solvent drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wet electrode process is used, then manufacturing cost is reduced and flexibility is improved, but battery performance deteriorates due to water residue and production time increases
Solution Approach 1:
The patent changes the physical state parameter of the electrode from wet (liquid electrolyte) to dry (solid electrolyte), eliminating water residue issues while maintaining manufacturing flexibility. This parameter change resolves the contradiction by allowing cost-effective manufacturing without the performance degradation caused by water in wet electrodes.
Solution Approach 2:
The patent extracts and removes the water component from the electrode structure, transitioning from a wet electrode containing liquid electrolyte to a dry electrode with solid electrolyte. This extraction eliminates the harmful effects of water residue on battery performance while preserving the manufacturing advantages of the wet process.
2Ease of manufacture
If a wet electrode process is used, then manufacturing cost is reduced, but production time increases due to drying requirements
Solution Approach 1:
By changing the electrolyte from liquid to solid state, the patent eliminates the drying step entirely. The solid electrolyte does not require evaporation or drying, thus reducing production time while maintaining the cost advantages of the wet electrode manufacturing process.
3Reliability
If a dry electrode process is used, then production time is reduced and performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the advantages of both wet and dry electrode processes by using a solid electrolyte that can be applied using wet processing techniques but performs like a dry electrode. This combination simplifies manufacturing while achieving the performance benefits of dry electrodes.
4Stability of the object's composition
If conventional mixing methods are used for electrode powder, then homogeneity is reduced and fine particles settle, but processing simplicity is maintained
Solution Approach 1:
The patent uses vibration during the mixing process to prevent fine particle settling and improve homogeneity. The vibration keeps particles suspended and evenly distributed, achieving better composition uniformity without significantly increasing process complexity.
Solution Approach 2:
The patent changes the physical state of the electrolyte to solid, which fundamentally alters the mixing behavior and particle distribution characteristics, improving homogeneity while maintaining processing simplicity.
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
The method ensures improved mechanical performance, flexibility, and reduces production costs by avoiding solvent drying and high-shear issues, enabling efficient manufacturing of high-quality dry electrodes.
Implementation Method 1
the solid electrolyte serves as a physical barrier between the positive and negative electrodes
Implementation Method 2
a sintering step is performed on a green body obtained by pressing a metal powder
Data Source
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AI summary
The present disclosure relates to powder for an electrode for manufacturing a dry electrode for a secondary battery, including an active material, a conductive material and a binder, and showing a resistivity of 700 S2 cm or less when being pressurized under a pressure of 50 MPa. The present disclosure also relates to a method for preparing the powder for an electrode, a method for manufacturing a dry electrode using the powder for an electrode, a dry electrode, a secondary battery including the dry electrode, an energy storage apparatus, and an apparatus for manufacturing a dry electrode.