Dry-Processed Electrode Binder Fibrillization
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Solution Overview
Problem
The use of PTFE binders in dry-processed electrodes for lithium-ion batteries leads to side reactions with lithium during charging, resulting in reduced initial efficiency and capacity loss.
Innovation Solution
A method involving the formulation of a dispersion binder and an aqueous binder into a glue liquid, which is then combined with a main binder and active materials, followed by drying and fibrillization to produce a dry-processed electrode. This process enhances the environment around the main binder, protecting it from reduction during charging and improving the bonding between active particles and conductive agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If PTFE binder is used in dry-processed electrodes, then the bonding between active particles is improved, but side reactions with lithium occur during charging, reducing initial efficiency
Solution Approach 1:
The patent introduces a protective coating layer as an intermediary substance between the PTFE binder and lithium ions. This coating prevents direct contact and chemical reaction between PTFE and lithium during charging, while allowing the PTFE to maintain its bonding function. The mediator resolves the contradiction by blocking the harmful interaction pathway without interfering with the beneficial bonding mechanism.
2Stability of the object's composition
If PTFE binder is used in dry-processed electrodes, then the electrode structure is stabilized, but capacity loss occurs due to lithium consumption in side reactions
Solution Approach 1:
The protective coating serves as a barrier that stabilizes the electrode structure by allowing PTFE to perform its binding function while preventing lithium consumption through side reactions. The mediator enables the system to maintain structural stability without the penalty of lithium capacity loss.
3Ease of manufacture
If conventional wet process is used for electrode manufacturing, then the slurry can be easily prepared, but the viscosity is higher and internal resistance is larger compared to dry process
Solution Approach 1:
The patent replaces the wet mechanical mixing process with a dry mixing approach. Instead of using liquid slurry that requires viscous mixing and solvent management, the invention uses dry粉末 mixing followed by compression, eliminating the viscosity and internal resistance issues inherent in wet processes while maintaining ease of manufacture through simplified material handling.
4Use of energy by stationary object
If dry process is used for electrode manufacturing, then the energy consumption is reduced and compaction is increased, but the initial efficiency is reduced due to PTFE-lithium side reactions
Solution Approach 1:
The protective coating acts as an intermediary that preserves the energy efficiency benefits of the dry process while eliminating the PTFE-lithium side reaction problem. The coating allows the dry process to maintain its low energy consumption and high compaction advantages without sacrificing initial efficiency.
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 proposed method significantly improves the initial efficiency of dry-processed electrodes by reducing side reactions and enhancing the bonding between components, leading to improved cycle stability and electrical properties of the battery.
Implementation Method 1
a dispersion binder and an aqueous binder are formulated into a glue liquid; dry-mixing an active material, a conductive agent, and a main binder to obtain a first dry material; adding the glue liquid to the first dry material for dispersion
Implementation Method 2
adding the glue liquid to the first dry material for dispersion, and performing a drying treatment to obtain a second dry material
Implementation Method 3
pulverizing the second dry material to form a binder-fibrillized powder
Data Source
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AI summary
The present disclosure provides a method of manufacturing a dry-processed electrode and a dry-processed electrode and use thereof. In the method, a new binder formulation including a main adhesive and a glue liquid containing a dispersion binder and an aqueous binder is used. The main adhesive and a raw material are dryly mixed to form a first dry material, and then the first dry material is dispersed by adding the glue liquid, and resulted second dry material is pulverized to obtain a powder after the main binder is fibrillized. The powder is calendered to obtain the dry-processed electrode.