Dry Electrode Composition for Flexible Crack-Resistant Batteries
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Solution Overview
Problem
Conventional methods for manufacturing dry electrodes result in low flexibility due to the use of high-shear mixing, leading to brittle materials and issues like powder floating, pinholes, and cracks, which are costly and time-consuming to address.
Innovation Solution
An electrode comprising a current collector with an electrode layer containing an active material, conductive material, binder, and fluoro-elastomer, with a flexural resistance of 10 mm Φ or less, using a manufacturing process that includes kneading, pulverizing, and calendering to form a film laminated on the current collector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high-shear mixing is used to manufacture dry electrodes, then the electrode can be formed without solvent, but the flexibility of the electrode deteriorates
Solution Approach 1:
The patent changes the mixing parameters by using low-shear mixing instead of high-shear mixing, and controls the mixing time and temperature to prevent excessive binder fibrilization and material brittleness, thereby maintaining flexibility while achieving solvent-free manufacturing
Solution Approach 2:
The patent uses a composite binder system consisting of multiple components with different functions, where one binder provides adhesion while another maintains flexibility, creating a synergistic effect that resolves the contradiction between manufacturing ease and flexibility
2Ease of manufacture
If high-shear mixing is used to manufacture dry electrodes, then the electrode can be formed without solvent, but defects such as powder floating, pinholes, and cracks occur
Solution Approach 1:
The patent optimizes mixing parameters including shear rate, mixing time, and temperature to achieve uniform material distribution without generating defects, thereby reducing the defect rate while maintaining solvent-free manufacturing advantages
Solution Approach 2:
The patent introduces a specific binder composition that acts as an intermediary material to hold powder particles uniformly without causing floating or aggregation, preventing pinholes and cracks during the solvent-free manufacturing process
3Manufacturing precision
If conventional drying apparatus is used to remove solvent uniformly, then drying uniformity improves, but manufacturing cost and time increase
Solution Approach 1:
The patent extracts and eliminates the solvent from the electrode manufacturing process entirely, adopting a dry electrode approach that removes the need for complex drying apparatus while achieving uniform electrode formation through optimized mixing and calendering processes
Data Source
AI summary
An electrode includes: an electrode current collector; and an electrode layer disposed on the electrode current collector and containing an active material, a conductive material, a binder and a fluoro-elastomer. The electrode has a flexural resistance of 10 mm Φ or less. A secondary battery including the electrode, and an energy storage system are also disclosed