Dry Electrode Film Processing for Binder Fibrilization Control

The mixing process is divided into multiple stages with different shear rates. A low-shear mixing stage is used first to prevent active material micronization, followed by a high-shear mixing stage to achieve binder fibrilization. This segmentation allows each mixing stage to perform its specific function without compromising the other, resolving the contradiction between maintaining active material particle size and achieving binder fibrilization.

The mixing process uses dynamic adjustment of shear rate throughout the mixing cycle. The shear rate is kept low during initial mixing to protect active material particles, then increased to high levels for binder fibrilization. This dynamic control of mixing intensity allows the system to adapt to different process requirements at different times, preventing micronization while achieving maximum binder fibrilization.

The solvent is completely extracted from the electrode mixture before the drying process. By removing all solvent through filtration or decantation prior to drying, there is no solvent remaining to evaporate and cause pinholes or cracks in the electrode active layer. This extraction approach eliminates the harmful evaporation process while still achieving complete solvent removal.

The solvent removal step is performed as a preliminary action before drying. By completely removing solvent through filtration or decantation before the drying process begins, the subsequent drying step only needs to remove moisture, which occurs without forming pinholes or cracks. This preliminary solvent extraction prevents the formation of defects that would otherwise occur during solvent evaporation.

The solvent is extracted and removed before drying, eliminating the need for prolonged drying processes. This preliminary removal of bulk solvent through filtration or decantation allows subsequent drying to be completed quickly and uniformly without the need for expensive, time-consuming controlled drying equipment, thus maintaining drying uniformity while improving productivity.

The process uses simple, inexpensive drying methods rather than expensive, complex drying equipment. By removing solvent beforehand through basic filtration or decantation, the drying step can be performed using simple ovens or even air drying, replacing the need for costly controlled atmosphere drying equipment while achieving sufficient drying uniformity.

The mixing process is segmented into low-shear and high-shear stages. The low-shear stage mixes ingredients without causing active material micronization, while the subsequent high-shear stage achieves充分的 binder fibrilization. This segmentation allows the dry manufacturing process to achieve both electrode quality and binder fibrilization without the compromises of single-stage mixing.

The mixing process dynamically adjusts shear rate to match process requirements. Low shear is applied during initial mixing to protect active material particles in the dry state, then high shear is applied to achieve maximum binder fibrilization. This dynamic control enables the dry manufacturing process to overcome the limitation of insufficient binder fibrilization while maintaining electrode quality.