Dry Electrode Mixing With Buffer Layer for Uniform Complexing
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Solution Overview
Problem
Existing methods for manufacturing dry electrodes in secondary batteries face challenges in effectively complexing electrode active material and conductive material, leading to inefficiencies and suboptimal electrical conductivity.
Innovation Solution
A method and apparatus that utilize a buffer layer to prevent material floating during mixing, ensuring uniform distribution of electrode active material on conductive material, and a separator system to ensure proper complexing and fiberization of binder, all within a single mixer, forming a high-quality dry electrode film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electrode active material and conductive material are mixed without a buffer layer, then mixing process is simpler, but material floating occurs leading to poor complexing
Solution Approach 1:
A buffer layer made of inert material (e.g., alumina or silica beads) is introduced as an intermediary between the electrode active material and conductive material. This buffer layer prevents direct floating of conductive material while enabling effective complexing through mechanical action during mixing, thus maintaining manufacturing precision without significantly increasing process complexity
Solution Approach 2:
The buffer layer is prepared and positioned in the mixer before adding the electrode active material and conductive material. This preliminary arrangement ensures that when the materials are added, the buffer layer is already in place to prevent floating and facilitate proper mixing, improving material distribution uniformity from the start of the process
2Manufacturing precision
If multiple mixers are used for complexing and fiberization, then mixing effectiveness is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the complexing and fiberization processes into a single mixer by introducing a buffer layer that enables both functions simultaneously. The buffer layer prevents material floating during complexing while also facilitating fiberization of the binder through mechanical action, thus achieving effective mixing without requiring multiple separate mixers
Solution Approach 2:
The buffer layer serves multiple functions within a single mixer: it prevents floating of conductive material, facilitates complexing between electrode active material and conductive material, and enables fiberization of the binder. This multi-functionality allows one mixer to perform what traditionally required multiple devices, reducing device complexity while maintaining mixing effectiveness
3Manufacturing precision
If conductive material is added first, then electrode active material can be distributed, but conductive material floating occurs reducing electrical conductivity
Solution Approach 1:
The buffer layer acts as an intermediary that prevents conductive material from floating when electrode active material is added. The inert buffer beads provide a stable medium that allows proper distribution of electrode active material while keeping conductive material in place, thus maintaining both distribution precision and electrical conductivity
Solution Approach 2:
The buffer layer creates a uniform mixing environment where all materials are distributed at similar energy levels, preventing gravitational settling or floating of conductive material. This equipotential mixing ensures that conductive material remains uniformly distributed throughout the electrode structure, maintaining reliable electrical conductivity
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 and apparatus enhance electrical conductivity and energy density of the dry electrode, reducing manufacturing time and costs by achieving effective complexing and fiberization without additional mixers, resulting in a high-quality dry electrode suitable for secondary batteries.
Implementation Method 1
a vacuum conveyor configured to deliver a material including an electrode active material, a conductive material, and a binder
Data Source
AI summary
A method for manufacturing a dry electrode for a secondary battery is described, involving the use of a mixer to combine materials without the use of solvents. The process begins by supplying a conductive material into the mixer, followed by the distribution of an electrode active material onto the conductive material. The mixer is then driven to ensure thorough mixing and complexing of the materials. A binder is introduced after the active material and conductive material have been combined, and the mixer is driven again to fiberize the binder. The resulting dry electrode mixture is then formed into a film using a roll press. This method allows for efficient production of dry electrodes with improved energy density and reduced manufacturing time and cost, offering a solvent-free alternative to traditional wet processes.