Dry Electrode Sheet Manufacturing via Binder Solution Pre-coating
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Solution Overview
Problem
The peel strength of active material layers formed by depositing powder of granulated particles is lower compared to those formed by coating a mixture paste and drying, due to a smaller contact area of the binder, but the paste method is more costly.
Innovation Solution
A method involving preparing a current collector, granulated particles with active material and binder, applying a binder solution, feeding and pressing the granulated particles, and enhancing adhesive strength, either by adding a solvent or imparting shearing stress, to increase the binder's contact area and peel strength while maintaining low manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the active material layer is formed by depositing powder of granulated particles, then the manufacturing cost is reduced, but the peel strength of the active material layer becomes lower
Solution Approach 1:
A binder solution is applied to the current collector before depositing the granulated particles. This preliminary binding action creates adhesive sites on the current collector surface, ensuring that when granulated particles are deposited and pressed, they achieve sufficient peel strength without requiring a subsequent drying step, thus maintaining low manufacturing cost while improving adhesion
Solution Approach 2:
The invention changes the physical state and timing of binder application by using a binder solution applied before particle deposition, rather than relying on binder within the granulated particles alone. This parameter change in the manufacturing process enables sufficient adhesive strength to be achieved during the pressing step without requiring drying, resolving the contradiction between cost and peel strength
2Strength
If the active material layer is formed by coating a mixture paste and drying the paste, then the peel strength of the active material layer is improved, but the manufacturing cost increases
Solution Approach 1:
The invention extracts and eliminates the drying step from the manufacturing process by applying the binder solution before particle deposition. This allows the binder to perform its adhesive function during the pressing step without requiring thermal drying, thereby reducing manufacturing cost while maintaining sufficient peel strength through the preliminary binder application
3Device complexity
If the granulated particles are pressed against the current collector, then the manufacturing process is simplified, but the contact area of the binder becomes small
Solution Approach 1:
The binder solution is applied to the current collector before granulated particles are deposited. This preliminary action ensures that the binder is already present on the current collector surface in a state that maximizes contact area with the particles during pressing, eliminating the need for complex subsequent drying and heating processes while achieving sufficient adhesive contact
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 improves the peel strength of the active material layer while reducing manufacturing costs, potentially matching the performance of the paste method without the need for a drying step, thus offering a cost-effective solution for lithium-ion secondary battery electrode sheets.
Implementation Method 1
applying a binder solution, feeding and pressing the granulated particles, and enhancing adhesive strength
Implementation Method 2
enhancing adhesive strength of the powder material by adding a solvent
Implementation Method 3
pressing the powder material of the granulated particles against the current collector
Implementation Method 4
enhancing adhesive strength of the powder material by imparting shearing stress
Data Source
AI summary
In a method of manufacturing a lithium-ion secondary battery electrode sheet proposed herein, a current collector (11), a powder material (13) of granulated particles, and a binder solution (12) are prepared. The binder solution (12) is applied onto the current collector (11). Subsequently, the powder material (13) of the granulated particles is fed onto the current collector (11). (Then, the powder material (13) of the granulated particles is pressed against the current collector (11). In the basic manufacturing method, adhesive strength of the powder material (13) of the granulated particles is enhanced after the powder material (13) of the granulated particles is fed onto the current collector (11) and before or while the powder material (13) of the granulated particles is pressed against the current collector (11).