Dry Composite Electrode Coating for Uniform Electrostatic Deposition
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Solution Overview
Problem
Conventional battery manufacturing processes rely on solvent-based approaches that pose handling and safety issues, require drying times, and result in non-uniform electrode coatings, which affect energy density, power density, and cycle life.
Innovation Solution
Employing an electrostatic deposition process to form composite particles with deagglomerated binder and conductive particles adhered to active material particles, allowing for solvent-free coating application onto a conductive current collector, ensuring uniformity and stability during deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based approaches are used to form electrode coating layers, then the electrochemical active materials and conductive particles can be applied onto the current collector, but handling and safety issues arise, drying time is required, and uniformity of the coating is compromised
Solution Approach 1:
The patent changes the physical state of the coating material from liquid (solvent-based) to solid (dry composite particles). This parameter change eliminates the need for solvent handling and drying, while enabling direct deposition of uniform coating layers through electrostatic forces.
Solution Approach 2:
The patent replaces the liquid flow and evaporation mechanism with an electrostatic deposition mechanism. Dry composite particles are deposited onto the current collector using electrostatic forces, substituting the mechanical/thermal drying process with an electrical field-based deposition process.
2Ease of manufacture
If solvent-based approaches are used to form electrode coating layers, then the electrochemical active materials can be applied onto the current collector, but drying time is required which reduces productivity
Solution Approach 1:
The patent extracts and removes the solvent component from the coating formulation, leaving only the essential dry composite particles (electrochemical active materials, conductive particles, and binder). This extraction eliminates the drying step entirely, significantly reducing manufacturing time and improving productivity.
Solution Approach 2:
The patent skips the drying step entirely by using dry composite particles instead of solvent-based slurries. The coating layer is formed directly through electrostatic deposition without requiring time for solvent evaporation, thus rushing through the manufacturing process and improving productivity.
3Ease of manufacture
If conventional solvent-based methods are used, then coating can be applied, but uniform dispersion and density control are difficult to achieve
Solution Approach 1:
The patent introduces binder particles as an intermediary material that surrounds and binds the electrochemical active material particles together in the composite particle structure. This intermediary ensures uniform dispersion and maintains consistent density during electrostatic deposition, achieving precise and uniform coating layers.
Solution Approach 2:
The patent uses composite particles consisting of electrochemical active materials, conductive particles, and binder materials in specific ratios. This composite structure ensures uniform dispersion of all components and enables precise control of coating density and uniformity during the electrostatic deposition process.
4Productivity
If dry composite particles are used in electrostatic deposition, then handling and safety issues are eliminated and drying time is removed, but particle separation forces must be overcome during deposition
Solution Approach 1:
The patent performs preliminary action by pre-forming composite particles with binder materials surrounding the electrochemical active material particles before deposition. This preliminary binding ensures that particles have sufficient adhesion strength to withstand separation forces during electrostatic charging and fluidization, while still enabling efficient deposition.
Solution Approach 2:
The patent creates composite particles with binder materials that provide the necessary mechanical strength to resist particle separation during the electrostatic deposition process. The composite structure maintains particle integrity throughout handling, charging, and deposition, enabling high productivity without sacrificing adhesion strength.
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 method achieves high-performance electrodes with improved uniformity and consistency, reducing manufacturing costs and energy consumption while enhancing energy storage device performance.
Implementation Method 1
depositing dry composite particles onto a conductive substrate by an electrostatic deposition process
Implementation Method 2
binder particles surrounding the active material particle, the binder particles generally being formed from deagglomeration of binder agglomerates and adhering relative to the surface of the active material particle through particle-to-particle adherence forces
Data Source
AI summary
An electrode for an electrochemical energy storage device formed from an electrostatic deposition process employs a composite particle including active material (AM) particle with adhered binder and optionally conductive particles formed with sufficient interaction forces between the individual ingredient particles to form an effective composite particle which can overcome particle separation during electrostatic charging, fluidization, and/or mechanical conveyance. Secondary binder particles undergo deagglomeration to form sub particles, which are adhered to the AM particles having a predetermined morphology. Smaller conductive particles, typically carbon black (CB) or similar carbon, are bound to the binder and adhere to the AM particles. The result is a composite particle adhered for withstanding separation forces imposed from electrostatic deposition onto a current collector. Application of a plurality of composite particles onto a conductive current collector in a uniform pattern and defined loading promotes robust energy density, power density, and cycle life for an electrochemical energy storage device.