Dry Powder Electrode Coating With Selective Bare Regions
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Solution Overview
Problem
Existing methods for producing electrochemical cell electrodes using slurry processes require extensive drying times and energy consumption due to solvent evaporation, and continuous coating methods result in uniform layers that complicate lead attachment and increase resistance.
Innovation Solution
A system using movable masks to selectively mask regions on a substrate during dry powder coating, allowing for non-coated areas for lead attachment and reducing resistance by heating the substrate through bare regions, enabling efficient deposition of multiple layers without solvent use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If slurry coating method is used, then electrode material can be deposited on substrate, but extensive drying time and energy consumption are required due to solvent evaporation
Solution Approach 1:
The invention changes the physical state of the coating material from liquid slurry to dry powder, eliminating the need for solvent evaporation. This parameter change from liquid to solid form fundamentally alters the drying process, requiring no thermal energy for solvent removal while maintaining effective electrode material deposition.
Solution Approach 2:
The invention extracts and removes the solvent component entirely from the coating process. By using dry powder instead of slurry, the harmful solvent evaporation step is completely eliminated, thereby removing the associated energy consumption and environmental concerns while preserving the essential function of electrode material deposition.
2Productivity
If continuous coating method is used, then electrode layers can be formed, but uniform coating results in complications for lead attachment and increased resistance
Solution Approach 1:
The invention applies local quality by creating non-uniform coating patterns with designated bare regions on the substrate. These localized bare areas serve specific functions for lead attachment, while other regions receive the coating material. This spatial variation in coating quality optimizes both productivity and reliability by ensuring proper electrical connections while maintaining efficient electrode layer formation.
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 reduces energy consumption and facilitates efficient lead attachment by minimizing resistance, allowing for consistent and efficient formation of electrochemical cell layers.
Implementation Method 1
heating the substrate through bare regions
Implementation Method 2
spraying first particles comprising at least one selected from the group of an electrochemical material, an ionically conductive material, an electrically conductive material, and a separator material towards the heated substrate to form a first layer on the substrate
Data Source
AI summary
A system for forming a particle layer on a substrate may include at least one sprayer and at least two masks configured to selectively mask a substrate in a first region and second region of the substrate. The at least one sprayer may be configured to spray particles at the substrate, where the at least two masks maintain the first region and second region substantially free of the deposited material. A heater may be employed to heat the substrate as the particles are sprayed by the at least one sprayer onto the substrate.