Dry Electrode Binder Structure for Granule Cohesion

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Solution Overview

Problem

Existing electrode manufacturing processes face issues with bond strength between granules, leading to separation during the roll winding process, and the use of expensive dryers to address solvent evaporation issues is inefficient.

Innovation Solution

An electrode design incorporating granules with a first binder and second binder particles, where the second binder particles enhance cohesion between granules, improving adhesion strength and preventing separation during the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single binder is used in dry electrode manufacturing, then the manufacturing process is simple, but the bond strength between granules is insufficient causing separation during roll winding

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidbond strength between granules

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent uses a composite binder system consisting of two different binders with complementary functions: the first binder provides initial adhesion and the second binder enhances bond strength between granules. This composite approach resolves the contradiction by achieving strong bonding without complicating the manufacturing process, as both binders are applied in sequence during the same coating operation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The binding function is segmented into two distinct roles: the first binder handles granule-to-substrate adhesion while the second binder specializes in granule-to-granule bonding. This segmentation allows each binder to be optimized for its specific function, resolving the contradiction between manufacturing simplicity and bond strength by distributing the bonding tasks across two specialized components.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If expensive specialized dryers are used to achieve uniform solvent evaporation, then drying uniformity is improved, but manufacturing cost and time increase significantly

Engineering Contradiction:

Improvedrying uniformityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent extracts and eliminates the solvent from the electrode manufacturing process entirely by using a solvent-free binder system. This removes the need for expensive specialized drying equipment and lengthy drying cycles, resolving the contradiction by achieving uniform bonding without any drying step, thereby significantly improving manufacturing efficiency while maintaining precision.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the potential harm of solvent-related drying issues into a benefit by using a solvent-free system. This eliminates all drying-related problems including non-uniform evaporation, pinhole formation, and the need for expensive drying equipment, while the binders themselves provide the necessary adhesion without requiring thermal processing.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Strength

If binder content in granules is increased to improve bond strength, then granule cohesion improves, but electrode flexibility and electrochemical performance deteriorate

Engineering Contradiction:

Improvegranule bond strengthVSAvoidelectrode flexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent applies binder content at optimal partial levels rather than excessive amounts. The first binder is present at 1-5 wt% and the second binder at 0.1-1 wt% of the total electrode weight, which is sufficient to achieve strong granule bonding without over-bonding that would reduce flexibility. This partial action approach resolves the contradiction by providing just enough binding to prevent separation while maintaining electrode adaptability.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The patent implements local quality by having the first binder primarily located within the granules providing internal cohesion, while the second binder is applied externally to the granule surface providing inter-granule bonding. This spatial distribution of binding functions allows strong bonding where needed (between granules) while maintaining flexibility in other regions, resolving the contradiction between strength and adaptability.

Inventive Principle:

Principle #3Local quality

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 improved bond strength enhances the manufacturing efficiency of electrodes by preventing granule separation, resulting in higher quality and reduced manufacturing costs.

Implementation Method 1

second binder particles... enhance cohesion between granules, improving adhesion strength and preventing separation

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentEP4693500A1Electrode, manufacturing method thereof, and electrochemical device comprising same

Publication Date: 2026.02.11 LG ENERGY SOLUTION LTD

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AI summary

There are disclosed an electrode including a current collector and an electrode active material layer located on at least one surface of the current collector, wherein the electrode active material layer includes granules including an electrode active material and a first binder; and second binder particles, a method for manufacturing the same, and an electrochemical device including the same.