Dry Roller Compression for Uniform All-Solid-State Battery Electrodes
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Solution Overview
Problem
Conventional wet processes for manufacturing electrodes for all-solid-state batteries result in non-uniform production and high manufacturing costs, with issues such as swelling of binders and difficulties in achieving uniform thickness.
Innovation Solution
A dry manufacturing method using first and second rollers of different sizes to compress a mixture of solid electrolyte and active material, forming an electrode sheet and composite sheet, which are then rolled to achieve the desired thickness and porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wet process is used to manufacture electrodes for all-solid-state batteries, then the electrode can be formed with binder materials, but the electrode thickness becomes non-uniform and manufacturing cost increases
Solution Approach 1:
The patent changes the fundamental parameter of the manufacturing process from wet to dry. The dry process eliminates liquid binders and solvents, using only solid materials that are compressed directly. This parameter change resolves the swelling issue that causes non-uniform thickness, as solid materials do not exhibit the same swelling behavior as liquid binders during processing.
Solution Approach 2:
The patent extracts and eliminates the binder component from the electrode structure. By removing the binder material entirely and relying on direct compression of active materials and solid electrolytes, the process avoids the swelling and uniformity issues associated with binders, while still achieving coherent electrode structure through mechanical compression.
2Ease of manufacture
If a wet process is used to manufacture electrodes for all-solid-state batteries, then the electrode can be formed with binder materials, but the manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the binder component from the electrode structure. By removing the binder material entirely and relying on direct compression of active materials and solid electrolytes, the process avoids the swelling and uniformity issues associated with binders, while still achieving coherent electrode structure through mechanical compression.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (using binders to hold materials together) with a mechanical compression mechanism. The dry compression process uses mechanical force to densify and consolidate the electrode materials, eliminating the need for chemical binders and their associated processing steps.
3Force
If conventional rolling methods are used, then the electrode can be compressed, but the porosity and thickness uniformity are compromised
Solution Approach 1:
The patent segments the compression process into multiple stages using rollers of different diameters. The first roller (smaller diameter) applies initial compression, and the second roller (larger diameter) applies final compression. This segmentation allows progressive densification while maintaining thickness uniformity, as each stage builds upon the previous one without causing localized deformation.
Solution Approach 2:
The patent introduces dynamic adjustment of roller diameters and compression forces. By using rollers with different diameters and adjusting their compression forces, the process adapts to the evolving properties of the electrode material during compression, maintaining uniform pressure distribution and preventing localized deformation that would compromise thickness uniformity.
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 enables the production of electrodes with uniform thickness and high porosity, reducing manufacturing costs and improving efficiency by eliminating the need for drying processes and minimizing binder swelling.
Implementation Method 1
manufacturing an electrode sheet by compressing the mixture for an electrode with at least one pair of first rollers
Implementation Method 2
obtaining an electrode for an all-solid-state battery by compressing the composite sheet with at least one pair of second rollers
Data Source
AI summary
An apparatus for manufacturing an electrode for an all-solid-state battery includes a plurality of pairs of first rollers configured to compress a mixture including a solid electrolyte and an active material to discharge an electrode sheet. The apparatus also includes at least one pair of second rollers that are spaced apart from the plurality of pairs of first rollers by a certain distance and that is configured to receive the electrode sheet from the plurality of pairs of first rollers and to compress the electrode sheet to discharge the electrode.