Dry Roller Electrode Coating for Basis Weight and Density Control
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Solution Overview
Problem
Existing methods for producing battery electrodes are complex, costly, and energy-intensive, particularly when it comes to achieving precise adjustment of layer surface mass and electrode density, and are limited in their ability to produce two- or multi-layer electrodes or coat both sides effectively.
Innovation Solution
A method involving a conductive substrate passed through at least two rollers, where a powder or granular mixture comprising active materials and binders is applied directly to the rollers, allowing for precise control of layer thickness and density, decoupling the setting of basis weight and electrode density, and enabling the production of electrodes with multiple layers or double-sided coatings using a minimal number of rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wet coating followed by drying is used to produce battery electrodes, then coating can be applied to the substrate, but the process requires several tens of meters long dryers, resulting in high energy consumption and limited throughput speed
Solution Approach 1:
The invention changes the fundamental parameter of coating application from wet coating to dry coating. Instead of applying a liquid suspension that requires extensive drying, the patent uses dry powder mixtures that are directly applied to the substrate and then compacted using calender rollers. This parameter change eliminates the need for long drying tunnels and associated high energy consumption while maintaining effective coating application.
Solution Approach 2:
The invention replaces the thermal drying system (heat-based evaporation of solvent) with a mechanical compaction system (calender rollers that press the dry powder into the substrate). This substitution eliminates the need for energy-intensive drying while achieving the same functional result of forming a solid coating layer on the electrode substrate.
2Manufacturing precision
If a large number of calender rolls are used to achieve predefined basis weight in dry coating, then coating density can be adjusted, but the process becomes complex and cannot produce two- or multi-layer electrodes
Solution Approach 1:
The invention segments the calendering process into distinct stages with specific functions. Instead of using many calender rolls, the patent employs a sequence of rollers where some are dedicated to applying powder coatings and others to compacting them. This segmentation allows independent control of coating application and compaction, enabling precise basis weight adjustment with fewer rollers and making multi-layer electrode production feasible.
Solution Approach 2:
The invention adds the dimension of temporal sequencing to the coating process. By applying different powder coatings at different times/stages through the roller sequence, the system can produce multi-layer electrodes without increasing the number of rollers. Each roller pair handles a specific layer, and the layered structure is built up sequentially as the substrate passes through the system.
3Adaptability or versatility
If double-sided coating is implemented in traditional processes, then both sides of the electrode can be coated, but the process becomes complex and cost-intensive
Solution Approach 1:
The invention merges the double-sided coating process into a single integrated pass through the roller system. By configuring rollers to apply coatings to both sides of the substrate simultaneously or in immediate sequence during one continuous operation, the patent eliminates the need for separate coating lines or complex repositioning mechanisms, thereby reducing overall device complexity and cost while maintaining double-sided coating capability.
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 allows for a technically simple, energy-efficient, and cost-effective production of electrodes with precise control over layer surface mass and density, enabling the production of both single- and double-sided coated electrodes with varying layer thicknesses and compositions.
Implementation Method 1
a conductive substrate is passed through at least two rollers, in particular calender rollers
Data Source
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AI summary
A method for coating an electrically conductive substrate with at least one powdered or granular mixture is disclosed, wherein the conductive substrate is guided through at least two rollers, in particular calender rollers, wherein the powdered or granular mixture is applied directly to at least one of the at least two rollers and a layer mass and/or a layer shape of the mixture is set on the roller, and wherein the mixture applied to the at least one of the at least two rollers is applied by at least one of the at least two rollers to at least one side of the conductive substrate. Furthermore, a method for manufacturing an electrode is disclosed.