Electrode Binder Powder Particle Sizing for Dry-Process Adhesion
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Solution Overview
Problem
The bonding strength between the current collector and the electrode active material layer in non-aqueous secondary batteries produced by a dry process is typically low.
Innovation Solution
A binder powder containing a particulate polymer with specific average primary particle diameter and controlled proportions of larger particles, ensuring high particle diameter uniformity and a glass transition temperature within a certain range, is used to enhance bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a dry process is used to produce electrodes, then production efficiency is improved, but bonding strength between current collector and electrode active material layer deteriorates
Solution Approach 1:
The invention changes the particle size parameters of the binder polymer, specifically setting the average primary particle diameter to 0.3 μm or more and controlling the proportion of particles larger than 250 μm to 10% by weight or less. This parameter optimization enables the dry process to achieve both high productivity and sufficient bonding strength by improving particle packing density and distribution uniformity.
Solution Approach 2:
The invention creates a composite structure in the electrode active material layer where the binder powder with controlled particle size distribution works synergistically with the electrode active material particles. This composite arrangement ensures efficient packing and strong bonding between the current collector and electrode layer while maintaining the advantages of dry process production.
2Ease of manufacture
If particle size distribution is not controlled, then manufacturing complexity is reduced, but bonding strength deteriorates
Solution Approach 1:
The invention establishes specific parameter ranges for particle size distribution (average primary particle diameter ≥0.3 μm, particles >250 μm ≤10% by weight) that balance manufacturing feasibility with bonding performance. These parameters are optimized to achieve good bonding strength without requiring overly complex manufacturing processes.
3Strength
If average primary particle diameter is small, then bonding strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
The invention sets the average primary particle diameter to 0.3 μm or more, which is sufficiently small to ensure good bonding strength but large enough to avoid excessive manufacturing precision requirements. This parameter represents an optimal balance point where bonding performance is maintained while manufacturing becomes more feasible.
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
The binder powder achieves excellent bonding strength between the current collector and the electrode active material layer, resulting in improved electrode performance.
Implementation Method 1
the bonding strength between the current collector and the electrode active material layer is increased
Data Source
AI summary
A binder powder for a non-aqueous secondary battery electrode, comprising a particulate polymer having an average primary particle diameter of 0.3 µm or more, wherein a proportion of particles having a particle diameter greater than 250 µm is 10% by weight or less.