Dry Electrode Films With Microparticulate Binders for Stronger Adhesion

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Solution Overview

Problem

Existing dry electrode films in energy storage devices face limitations in composition and performance due to mechanical properties, such as poor adhesion and cohesion, leading to increased cell resistance and reduced energy storage capacity, particularly when using traditional high shear processing methods.

Innovation Solution

Incorporation of microparticulate non-fibrillizable binders, such as cellulose derivatives, with particle sizes ranging from 0.5 to 40 μm, and a combination with fibrillizable binders, processed through jet milling and calendering to form self-supporting electrode films, ensuring uniform distribution and improved mechanical characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional high shear processing methods are used to fabricate dry electrode films, then the fabrication process is relatively simple, but the electrode films exhibit poor adhesion and cohesion leading to increased cell resistance and reduced energy storage capacity

Engineering Contradiction:

Improveadhesion and cohesionVSAvoidfabrication process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the particle size parameter of the binder from conventional sizes to microparticulate sizes (0.5-40 μm), which fundamentally alters the binder's ability to adhere to active material particles and form cohesive films during dry processing, thereby improving adhesion and cohesion without requiring complex fabrication processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite binder systems combining microparticulate non-fibrillizable binders (for adhesion to active material) with fibrillizable binders (for film cohesion), creating a multi-functional binder composite that simultaneously addresses both adhesion and cohesion requirements in dry electrode fabrication

Inventive Principle:

Principle #40Composite materials

2Strength

If microparticulate non-fibrillizable binders with particle sizes of 0.5 to 40 μm are incorporated into dry electrode films, then tensile strength and mechanical characteristics are improved, but the device complexity increases due to specialized processing requirements

Engineering Contradiction:

Improvetensile strengthVSAvoidprocessing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent changes the particle size parameter of the binder to microparticulate dimensions (0.5-40 μm), which fundamentally alters the binder's ability to adhere to active material particles and form cohesive films during dry processing, thereby improving adhesion and cohesion without requiring complex fabrication processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces traditional mechanical mixing and high shear processing with jet milling technology, which uses controlled particle collision and erosion mechanisms to achieve uniform binder distribution and film formation, simplifying the overall processing while improving mechanical properties

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If jet milling and calendering processes are used to form self-supporting electrode films, then uniform distribution of materials and improved mechanical characteristics are achieved, but the manufacturing time and process steps increase

Engineering Contradiction:

Improveuniform distributionVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent performs preliminary size reduction of the binder to microparticulate dimensions (0.5-40 μm) before electrode fabrication, which enables uniform distribution to be achieved more quickly during subsequent jet milling and calendering processes, reducing overall manufacturing time while maintaining high precision

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12512478B2Compositions and methods for dry electrode films including microparticulate non-fibrillizable binders

Publication Date: 2025.12.30 TESLA INC

AI summary

Provided herein are dry process electrode films, and energy storage devices incorporating the same, including a microparticulate non-fibrillizable binder having certain particle sizes. The electrode films exhibit improved mechanical and processing characteristics. Also provided are methods for processing such microparticulate non-fibrillizable electrode film binders, and for incorporating the microparticulate non-fibrillizable binders in electrode films.