Dry Electrode Extrusion With Sensor Feedback for Uncoated Width Control
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Solution Overview
Problem
Existing rechargeable lithium batteries face challenges in achieving high energy density and safety, particularly due to the risk of fire or explosion from flammable organic electrolyte solutions, and there is a need to minimize the uncoated portion in dry electrodes to enhance capacity and energy density.
Innovation Solution
A manufacturing apparatus and method that includes a dry mixture supply part, extrusion part, lamination part, and sensor to control the width of the uncoated portion in the electrode active material layer, allowing for a dry electrode with specific coated and uncoated sections, and a method to adjust the supply amount of the dry mixture to form a structured electrode active material layer on a current collector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the uncoated portion area is reduced to improve capacity and energy density, then the capacity and energy density are improved, but the manufacturing precision and control difficulty increase
Solution Approach 1:
The patent employs a feeding shutter with adjustable opening width that can be dynamically controlled during the extrusion process. This dynamic adjustment mechanism allows the uncoated portion width to be precisely controlled while maintaining high capacity and energy density, resolving the contradiction between manufacturing precision and quantity of substance.
Solution Approach 2:
The patent incorporates a sensor part that detects the uncoated portion and provides feedback to the control system. This feedback mechanism enables real-time monitoring and adjustment of the uncoated portion width, ensuring precise control while optimizing capacity and energy density through iterative refinement.
2Reliability
If all-solid-state battery design is adopted to eliminate flammable electrolyte solutions and improve safety, then safety is improved, but the energy density and capacity may be reduced
Solution Approach 1:
The patent changes the physical and chemical parameters of the electrolyte system by transitioning from liquid organic electrolytes to solid electrolytes. This parameter change eliminates flammability while the optimized electrode structure with controlled uncoated portions compensates for any energy density loss, achieving both safety and performance goals.
3Manufacturing precision
If the feeding shutter opening width is adjusted to control uncoated portion width, then the uncoated portion width is controlled, but the device complexity increases
Solution Approach 1:
The patent segments the electrode width into distinct coated and uncoated portions using a feeding shutter mechanism. This segmentation approach allows independent control of the uncoated portion width through the adjustable shutter opening, achieving precise width control without requiring complex overall device architecture.
Data Source
AI summary
An apparatus for manufacturing a dry electrode, a method for manufacturing a dry electrode, and a dry electrode manufactured thereby are disclosed. The apparatus may include: a dry mixture supply part, a dry binder, and a dry conductive material, where the dry mixture supply part may include a feeding shutter to adjust a width of an opening through which the dry mixture is supplied; an extrusion part to form an electrode active material layer including a first coated portion, a second coated portion, and a third coated portion including a film formed from the dry mixture, where the electrode active material layer may further include an uncoated portion, which is an empty area and defined between the first coated portion and the third coated portion; a lamination part to laminate the electrode active material layer on an electrode current collector; and a sensor part to recognize the uncoated portion.