Battery Electrode Adhesion via Polymer Protrusions
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Solution Overview
Problem
The existing methods for producing battery electrodes result in decreased adhesive strength between the current collector and the electrode compound material layer, leading to potential peeling and reduced battery performance during production and use.
Innovation Solution
A method involving the formation of polymer protrusions on the current collector surface, followed by a binder solution layer and a compound material paste layer, which are then dried together to increase binder distribution at the interface, enhancing adhesion and preventing slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a compound material paste containing binder and active material is coated onto current collector and dried, then the electrode compound material layer is formed, but the binder gathers at the surface layer causing decreased adhesive strength between current collector and compound material layer
Solution Approach 1:
The patent applies preliminary action by forming polymer protrusions on the current collector surface before coating the compound material paste. These protrusions are created in advance to prevent binder migration during the subsequent drying process, thereby maintaining adhesive strength at the interface between the current collector and compound material layer.
Solution Approach 2:
The patent implements local quality by creating polymer protrusions at specific locations on the current collector surface where the compound material paste will be coated. These localized protrusions provide targeted adhesion enhancement exactly where needed at the interface, without affecting the overall uniformity of the electrode structure.
2Strength
If binder solution layer is formed before compound material paste layer, then adhesive strength is enhanced, but the production process complexity increases
Solution Approach 1:
The patent merges the binder solution layer formation and compound material paste coating into a single integrated process step. The polymer protrusions serve dual functions: they provide the adhesion enhancement that would otherwise require a separate binder layer, and they prevent binder migration during drying. This combination simplifies the overall production process while maintaining enhanced adhesive strength.
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 approach results in improved adhesive strength and flatness of the electrode surface, leading to enhanced battery performance, including high cycle durability and output characteristics.
Implementation Method 1
the compound material paste layer catches on the polymer protrusions. As a result, slippage of the compound material paste layer is prevented
Implementation Method 2
obtaining an electrode in which the compound material layer is formed on the current collector by drying both the deposited binder solution layer and compound material paste layer
Data Source
AI summary
A method is provided for producing a battery electrode having a configuration in which a compound material layer containing an active material and a binder is retained on a current collector. This method includes forming protrusions composed of a polymer on a surface of the current collector, forming a binder solution layer by coating a binder solution containing the binder over the polymer protrusions onto the current collector, depositing the binder solution layer and a compound material paste layer on the current collector by applying a compound material paste containing the active material over the binder solution layer, and obtaining an electrode in which the compound material layer is formed on the current collector by drying both the deposited binder solution layer and compound material paste layer.