Dry Electrode Film With Insulating Protective Layer
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Solution Overview
Problem
The manufacturing of electrochemical device electrodes often results in defects such as pinholes, cracks, and uneven drying, leading to poor insulation properties and processing inefficiencies, particularly when using slurry coating methods, and existing drying apparatuses are costly and inefficient.
Innovation Solution
A method involving a free-standing dry electrode film with a conductive primer layer and insulating protective layer is used, where the insulating protective layer is disposed to cover the lateral surface of the conductive primer layer, ensuring no gaps and improved adhesion, stability, and processing convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If slurry coating method is used to manufacture electrode, then electrode can be formed with flowable mixture, but defects such as pinholes, cracks, and uneven drying occur leading to poor insulation properties
Solution Approach 1:
The invention changes the fundamental parameter of electrode manufacturing from wet slurry coating to dry powder coating. This parameter change eliminates solvent-related defects (pinholes, cracks, uneven drying) while maintaining ease of manufacture through simple powder application and compression processes
Solution Approach 2:
The invention replaces the chemical-drying-based slurry coating system with a mechanical compression-based dry coating system. Instead of relying on solvent evaporation, the electrode is formed by compressing dry powder mixture between electrodes, eliminating drying-related defects and improving insulation reliability
2Reliability
If insulation portion is coated after electrode active material layer is formed through slurry coating, then insulation property is improved, but additional process management is required to minimize overlapped width with incline
Solution Approach 1:
The invention applies the preliminary action principle by forming the insulation layer together with the electrode active material layer in a single coating step, before any drying or compression process. This eliminates the need for subsequent insulation coating and avoids the complexity of managing overlaps with inclined surfaces
Solution Approach 2:
The invention merges the electrode active material layer formation and insulation layer formation into a single coating operation. Both layers are applied simultaneously in one step, eliminating the need for separate insulation coating processes and reducing overall process complexity
3Manufacturing precision
If slurry flows down before complete drying, then electrode shape deviates from designed shape, but drying process takes time and requires energy
Solution Approach 1:
The invention replaces the thermal drying process with a mechanical compression process. Instead of drying slurry to prevent flow-down, the dry powder mixture is directly compressed into the electrode shape, eliminating both drying time and the risk of slurry flow-down, achieving high shape accuracy without time loss
Data Source
AI summary
Disclosed is a method for manufacturing a dry electrode. In the method, a conductive primer layer and an insulating protective layer are formed in a single step, or the insulating protective layer is formed first before an electrode active material layer is formed and after the conductive primer layer is formed. In this manner, there is no gap between the insulating protective layer and the conductive primer layer, thereby providing further improved insulation property. In addition, since the dry electrode is manufactured by laminating the current collector having the conductive primer layer and the insulating protective layer with the dry electrode film, an electrode having excellent adhesion and improved stability can be obtained advantageously.