Dry Electrode Composition With Fiberizable Binder for Crack-Free Sheets
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Solution Overview
Problem
Existing lithium secondary battery manufacturing methods face issues such as solvent evaporation defects leading to pinholes and cracks, non-uniform drying causing particle migration, and high costs due to expensive drying devices, while dry electrode methods lack sufficient tensile strength and are cost-inefficient.
Innovation Solution
A dry electrode composition using a fiberizable binder and plasticizer, combined with calendering and kneading processes, to create a binder that forms fibrous structures, enhancing tensile strength and eliminating the need for solvent drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a solvent-based electrode slurry drying process is used, then the electrode mixture layer can be formed, but pinholes and cracks occur due to solvent evaporation defects
Solution Approach 1:
The invention extracts and removes the solvent from the electrode manufacturing process entirely. By using a dry mixing method where the binder is applied as a powder or granular material without solvent, the harmful evaporation process is eliminated, preventing pinholes and cracks while maintaining electrode quality.
Solution Approach 2:
The invention changes the physical state parameter of the binder from a dissolved slurry form to a dry powder or granular form. This parameter change eliminates the solvent evaporation step and its associated defects, while the binder's fibrous structure provides the necessary binding function.
2Manufacturing precision
If a solvent drying process is used to form an electrode layer, then the electrode mixture can be consolidated, but particle migration occurs due to non-uniform drying
Solution Approach 1:
The invention removes the solvent drying process entirely, replacing it with a dry consolidation method. This eliminates the non-uniform evaporation that causes particle migration, ensuring uniform particle distribution throughout the electrode layer while maintaining consolidation.
Solution Approach 2:
The invention replaces the thermal drying process with a mechanical consolidation approach. By applying pressure and using the fibrous binder structure to bind particles mechanically, uniform consolidation is achieved without the harmful effects of non-uniform solvent evaporation.
3Ease of manufacture
If a dry electrode manufacturing method is used to eliminate solvent drying, then manufacturing cost is reduced, but tensile strength is insufficient and cracks occur
Solution Approach 1:
The invention uses a composite binder structure consisting of fibrous materials with high tensile strength. The fibrous binder forms a network that mechanically reinforces the electrode, providing sufficient tensile strength while maintaining the cost-effective dry manufacturing process without solvent.
Solution Approach 2:
The invention changes the binder's physical form to fibrous structures with inherently higher tensile strength. This parameter change in the binder's morphology provides the mechanical strength needed for the dry electrode while maintaining manufacturing simplicity and cost-effectiveness.
4Manufacturing precision
If expensive drying devices are used to evenly dry the electrode mixture layer, then uniform drying can be achieved, but manufacturing cost and time increase significantly
Solution Approach 1:
The invention extracts and eliminates the expensive drying devices and drying process entirely. By using a binder that provides binding function without solvent, the manufacturing process becomes simpler, faster, and more cost-effective while achieving uniform electrode formation through mechanical consolidation rather than thermal drying.
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 produces electrodes with improved tensile strength and uniformity, reducing manufacturing costs by omitting solvent drying processes and enhancing processability.
Implementation Method 1
a particulate binder in which fibers aggregate to form bundles; and a plasticizer, wherein the binder is fiberizable by heat or pressure
Data Source
AI summary
A dry electrode composition including: an electrode active material; a particulate binder in which fibers aggregate to form bundles; and a plasticizer, wherein the binder is fiberizable by heat and pressure, a method for manufacturing a dry electrode sheet for a secondary battery using the dry electrode composition, and an electrode and a secondary battery including the dry electrode sheet are provided.