Secondary Battery Electrode Coating via Concave Convex Film
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Solution Overview
Problem
The existing methods for producing electrodes for secondary batteries, such as lithium ion batteries, face inefficiencies in the application of coating components, as the surface area of the active material layer in contact with the coating component is limited, restricting the effectiveness of the coating component's impact, particularly in the thickness direction of the electrode.
Innovation Solution
A method involving the use of a moisture powder with agglomerated particles in a pendular or funicular state, where the solid phase, liquid phase, and gas phase are balanced, allowing for a concave/convex shape to be formed on the coating film before drying, thereby increasing the surface area and enabling the coating component to be disposed in the thickness direction, using inorganic compounds like alumina or silicon-tin alloys to enhance mechanical strength and capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a coating solution is simply applied to the surface of the active material layer, then the coating process is simple, but the surface area in contact with the coating component is small and the effect of the coating component is insufficient
Solution Approach 1:
The invention forms a concave/convex shape on the coating film surface, transforming the flat surface into a curved topology with valleys and peaks. This curvature increases the surface area available for coating component deposition and allows the coating to penetrate into the concave regions, thereby enhancing the contact area between the active material layer and coating component while maintaining a relatively simple coating process
Solution Approach 2:
The invention transitions from a two-dimensional flat surface to a three-dimensional concave/convex structure. By creating depth variations on the coating film surface, the effective surface area is dramatically increased without significantly changing the planar footprint, enabling greater coating component uptake and improved electrochemical performance
2Ease of manufacture
If a coating solution is simply applied to the surface of the active material layer, then the coating process is simple, but the coating component effect is not sufficiently exhibited in the thickness direction
Solution Approach 1:
The concave/convex surface structure creates three-dimensional topography that allows coating components to be deposited not only on the outer surface but also within the concave valleys. This curvature-based structure enables the coating to extend into the thickness direction, increasing the quantity and effectiveness of coating component distribution throughout the electrode structure
Solution Approach 2:
The coating component is nested within the concave regions of the coating film structure. The valleys and depressions in the concave/convex surface act as receptacles that trap and retain coating materials, allowing the coating to be embedded within the electrode structure rather than merely surface-deposited, thereby enhancing effectiveness in the thickness direction
3Area of stationary object
If a concave/convex shape is formed on the coating film, then the surface area increases and coating component disposition is improved, but the process complexity increases
Solution Approach 1:
The concave/convex shape is formed on the coating film before the coating component is applied. By pre-forming the three-dimensional surface structure on the drying film, the substrate is prepared in advance to receive and retain the coating material in the desired configuration, simplifying the subsequent coating process while achieving enhanced surface area and coating effectiveness
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 significantly increases the surface area of the active material layer in contact with the coating component, enhances the mechanical strength of the electrode, and improves the battery's capacity while maintaining the concave/convex shape during charging and discharging, thereby overcoming the limitations of traditional methods.
Implementation Method 1
a solid phase, a liquid phase, and a gas phase form a pendular state or a funicular state
Implementation Method 2
a solid phase, a liquid phase, and a gas phase form a pendular state or a funicular state
Implementation Method 3
an existence form of solid components of agglomerated particles constituting a moisture powder and a solvent is close to a capillary state
Implementation Method 4
forming a desired concave/convex shape on a coating film and realizing an increase in a surface area of an active material layer
Data Source
AI summary
A method of producing an electrode disclosed here includes a step in which a moisture powder formed of agglomerated particles; a step in which a coating film composed of the moisture powder is formed using the moisture powder on the electrode current collector when a gas phase of the coating film remains; a step in which a concave/convex shape is formed on a surface part of the coating film; a step in which a coating material containing at least one type of inorganic compound is applied to the coating film on which the concave/convex shape is formed; and a step in which the coating film and the coating material are dried, and the electrode having an electrode active material layer and a coating component in a concave part of the concave/convex shape on the electrode active material layer is formed.