Electrode Plate Edge Adhesion via Localized Binder Control
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Solution Overview
Problem
The existing electrochemical apparatuses, such as lithium-ion batteries, face a challenge in improving electrical performance and safety while maintaining their volume-energy density, as the addition of a primer layer enhances adhesive force but reduces this density.
Innovation Solution
The electrode plate design includes a current collector with distinct edge and intermediate regions, where the active material layer has varying binder compositions and widths, resulting in higher adhesive forces at the edge regions compared to the intermediate region, preventing peeling without affecting volume-energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a primer layer is added between the current collector and active material layer to improve adhesive force, then the adhesive force is significantly improved, but the volume-energy density of the electrochemical apparatus is reduced
Solution Approach 1:
The patent applies different binder compositions and contents at different locations of the active material layer. Specifically, the edge regions use a first binder with higher adhesive force and higher binder content (5-15%), while the intermediate region uses a second binder with lower adhesive force and lower binder content (3-8%). This local differentiation ensures strong adhesion at the edges where peeling is most likely to occur, while maintaining high energy density in the intermediate region that contributes most to energy storage.
2Strength
If the binder content is increased to improve adhesive force, then the adhesive force is improved, but the volume-energy density is reduced
Solution Approach 1:
The patent implements spatially varying binder content across the active material layer. The edge regions contain higher binder content (5-15%) to provide enhanced adhesive force where mechanical stress and peeling are most likely to occur during battery operation. The intermediate region contains lower binder content (3-8%) to maximize the proportion of active material, thereby maintaining high volume-energy density. This localized optimization resolves the contradiction between adhesion strength and energy density.
3Reliability
If the adhesive force at edge regions is increased to prevent peeling, then the safety performance is improved, but the volume-energy density is reduced
Solution Approach 1:
The patent strategically enhances adhesive force only at the edge regions where peeling and safety issues are most likely to occur during battery assembly and operation. The first binder with higher adhesive force and content is applied specifically at the edges (width ratio of 5-15%), while the intermediate region maintains lower binder content to preserve energy density. This localized approach ensures safety performance without sacrificing overall volume-energy density.
4Ease of manufacture
If a primer layer is added to ensure processing performance, then the processing performance is improved, but the volume-energy density is reduced
Solution Approach 1:
The patent eliminates the need for a separate primer layer by incorporating adhesive force enhancement directly into the active material layer through spatially varying binder composition. The first binder with higher adhesive force is applied at the edge regions where processing and handling occur, providing sufficient processing performance without requiring an additional primer layer. This integration maintains high volume-energy density by avoiding the extra material layer.
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 design enhances electrical and safety performance by maintaining volume-energy density and improving adhesive forces, thereby preventing peeling and ensuring efficient operation of the electrochemical apparatus.
Implementation Method 1
a first adhesive force between the first portion and the current collector, and a second adhesive force between the second portion and the current collector, are both greater than a third adhesive force between the intermediate portion and the current collector
Data Source
Figure 1~3
AI summary
An electrode plate includes: a current collector (1), including, in a width direction, a first edge region (4), a second edge region (5), and an intermediate region (6) located between the first edge region (4) and the second edge region (5); and an active material layer (2) provided on the current collector (1). The active material layer (2) includes a first portion (7), a second portion (8), and an intermediate portion (9) respectively provided on the first edge region (4), the second edge region (5), and the intermediate region (6). A first adhesive force between the first portion (7) and the current collector (1) and a second adhesive force between the second portion (8) and the current collector (1), are both greater than a third adhesive force between the intermediate portion (9) and the current collector (1).