Dry Electrode Transfer Using an Interlayer for High Active Loading
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Solution Overview
Problem
Existing methods face challenges in introducing an electrode active material layer with high loading onto an electrode current collector without causing damage or separation during the process, which is crucial for high-capacity lithium batteries.
Innovation Solution
A method involving the use of an interlayer on the current collector, followed by a dry electrode film with anisotropic tensile strength, allowing for the separation of a second region from a first region to form a dry electrode without direct contact between the active material layer and the current collector, enabling easy adjustment of the active material layer's position and preventing separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the electrode active material layer thickness is increased to achieve high loading, then the energy capacity is improved, but the possibility of defects such as collapse of the electrode active material layer increases
Solution Approach 1:
The patent introduces a release film as an intermediary layer between the electrode active material layer and the current collector. This release film prevents direct contact, allowing the thick active material layer to be handled and positioned without transferring stress to the current collector, thereby preventing collapse while maintaining high loading.
Solution Approach 2:
The patent segments the electrode structure into distinct layers: the current collector, the release film, and the electrode active material layer. This segmentation allows each layer to perform its specific function independently, with the release film acting as a buffer that protects the current collector from the weight and potential collapse of thick active material layers.
2Ease of manufacture
If the electrode active material layer is introduced directly onto the current collector, then the manufacturing process is simplified, but the active material layer may separate from the current collector
Solution Approach 1:
The release film serves as a mediator that enables easy handling and positioning of the active material layer during manufacturing. The layer is first formed on the release film, positioned correctly, and then the release film is peeled off to transfer the layer to the current collector, ensuring proper adhesion without direct initial contact.
3Adaptability or versatility
If the active material layer position needs to be adjusted, then the manufacturing flexibility is improved, but the process complexity increases
Solution Approach 1:
The release film acts as a temporary carrier that allows the active material layer to be easily manipulated, moved, and repositioned before final attachment to the current collector. The layer can be adjusted on the release film without risk of damage or premature adhesion, providing manufacturing flexibility while maintaining process simplicity.
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
This method facilitates the formation of a dry electrode with a high active material loading while maintaining structural integrity, allowing for precise control over the active material layer's position and reducing the risk of separation from the current collector.
Implementation Method 1
the dry electrode film has anisotropic tensile strength
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A method of preparing a dry electrode includes arranging at least one interlayer on at least one surface of an electrode current collector to prepare a first stack, arranging a dry electrode film, which has an area larger than an area of the interlayer, on the first stack to prepare a second stack, wherein the dry electrode film includes a first region on the interlayer and a second region extending from the first region beyond an outer periphery of the interlayer, and pulling at least a portion of the second region of the dry electrode film to separate the second region from the first region and provide a dry electrode, wherein the dry electrode film has anisotropic tensile strength, and the dry electrode includes a dry electrode active material layer on the interlayer, but the dry electrode active material layer disposed directly on the electrode current collector is absent.