Electrode Particle Aggregates for Uniform Conductive Dispersion
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Solution Overview
Problem
Existing methods for manufacturing electrode plates using particle aggregates formed by agitation-type mixer granulators face challenges in achieving uniform dispersion of active material and conductive particles, leading to uneven distribution and reduced conductivity and energy density in the active material layer.
Innovation Solution
A manufacturing method involving the mixing of conductive particles with a binder dispersion followed by kneading with active material particles to form a clay-like mixture, which is then aggregated into wet particles, ensuring uniform dispersion and improved conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an agitation-type mixer granulator is used to mix and granulate active material particles, conductive particles, binder, and dispersion medium, then the particle aggregate can be manufactured, but the active material particles and conductive particles fail to disperse uniformly
Solution Approach 1:
The mixing process is divided into multiple sequential steps: first mixing conductive particles with binder dispersion, then adding active material particles, and finally granulating. This segmentation of the mixing process allows each component to be properly incorporated without aggregation, achieving uniform dispersion that a single-step mixing cannot accomplish.
Solution Approach 2:
Conductive particles are pre-mixed with binder dispersion before adding active material particles. This preliminary action ensures that conductive particles are evenly distributed in the binder matrix, preventing aggregation and ensuring uniform dispersion in the final particle aggregate.
2Productivity
If wet particles with unevenly dispersed active material and conductive particles are aggregated, then the particle aggregate can be formed, but the resulting undried active material film has uneven dispersion
Solution Approach 1:
Uniform dispersion is achieved in the wet particle stage through controlled sequential mixing before granulation. This preliminary uniform distribution is then maintained through the aggregation process, ensuring the undried active material film inherits the uniform dispersion from the wet particles.
Solution Approach 2:
The mixing conditions and sequence are optimized to achieve uniform dispersion at the wet particle level. By controlling particle size distribution, mixing speed, and addition sequence, the uniform dispersion is preserved during aggregation, resulting in homogeneous active material film formation.
3Device complexity
If conventional mixing methods are used, then the manufacturing process is simple, but the conductivity and energy density of the active material layer are reduced
Solution Approach 1:
The mixing process is segmented into controlled stages with specific parameters for each stage. While this increases process complexity compared to single-step mixing, it ensures proper dispersion and distribution of conductive particles, directly improving the conductivity and energy density of the final active material layer.
Solution Approach 2:
Optimized mixing parameters including sequential addition rates, mixing speeds, and particle size control are implemented. These parameter changes ensure maximum conductivity and energy density by achieving uniform particle distribution, justifying the increased process 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
This method ensures uniform dispersion of active material and conductive particles, enhancing the conductivity and energy density of the active material layer, while also reducing particle-size variation and preventing defects during the rolling process.
Implementation Method 1
a binder dispersion in which the binder is dispersed in the dispersion medium
Data Source
AI summary
A manufacturing method of a particle aggregate aggregated with wet particles in which active material particles and conductive particles are evenly dispersed and a manufacturing method of an electrode body including the particle aggregate are provided. The manufacturing method of a particle aggregate includes a first step of obtaining a first mixture by mixing conductive particles with a binder dispersion in which binder is dispersed in a dispersion medium, a second step of obtaining a clay-like mixture by kneading the first mixture with active material particles, and a third step of obtaining the particle aggregate aggregated with wet particles formed of the clay-like mixture.