Positive Electrode Intermediate Layer for Uniform Edge Coating
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Solution Overview
Problem
Existing electrodes face issues where the active material layer at the end portions becomes relatively thicker than the rest, leading to potential detachment and non-uniform thickness.
Innovation Solution
Incorporation of an intermediate layer between the collector layer and the active material layer, with specific manufacturing processes to ensure uniform thickness and adherence, using slurry application with controlled contact angles and solvents to form the layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the active material layer is applied directly onto the collector layer, then the manufacturing process is simple, but the active material layer at end portions becomes relatively thicker than the rest
Solution Approach 1:
An intermediate layer is introduced between the collector layer and the active material layer. This intermediate layer acts as a mediator that prevents the active material layer from becoming excessively thick at the end portions while maintaining a relatively simple manufacturing process. The intermediate layer is applied to the collector layer before applying the active material layer, creating a three-layer structure that resolves the thickness uniformity issue.
2Device complexity
If the active material layer is applied directly onto the collector layer, then the structure is simple, but the active material layer may detach from the collector layer
Solution Approach 1:
The intermediate layer serves as an intermediary between the collector layer and the active material layer, improving adhesion and preventing detachment. This intermediate structure enhances the reliability of the electrode by ensuring better bonding between the active material layer and the collector layer, while only moderately increasing the overall structural complexity.
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 solution effectively suppresses the thickness of the active material layer at the end portions, ensuring uniformity and adherence, thereby enhancing the electrode's stability and performance.
Implementation Method 1
the intermediate layer slurry is applied onto the positive electrode collector layer with a contact angle set to 1° or greater and 35° or smaller
Implementation Method 2
an intermediate layer slurry that contains particles and a solvent having volatility, and is to form the intermediate layer after being applied to the positive electrode collector layer
Data Source
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AI summary
An electrode (positive electrode 100) has a collector layer (positive electrode collector layer 110), an active material layer (positive electrode active material layer 120), and an intermediate layer (130). The active material layer (positive electrode active material layer 120) is stacked on and joined with the collector layer (positive electrode collector layer 110), and contains an active material (positive electrode active material 121). The intermediate layer (130) is disposed intermediate along a stacking direction (Z) between a side of an end portion (110b) of the collector layer (positive electrode collector layer 110) and an end portion (120b) of the active material layer (positive electrode active material layer 120), and joined with the collector layer (positive electrode collector layer 110) and the active material layer (positive electrode active material layer 120).