Electrode Porous Coating Layer via Electroemission
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Solution Overview
Problem
Manufacturing electrodes with inorganic particles-containing porous coating layers faces challenges in achieving uniform dispersion of inorganic particles, leading to potential short circuits and thermal instability in electrochemical devices.
Innovation Solution
A method involving the preparation of a sol solution from metal alkoxide compounds, electroemitting this solution to form a porous, non-woven coating layer of inorganic fibers on the electrode active material layer, and subsequent thermal treatment to create a uniformly dispersed, high-thermal-stability coating layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If inorganic particles are dispersed in binder polymer solution using physical agitation or ultrasonic dispersion, then the inorganic particles can be initially dispersed, but they agglomerate during solvent drying process
Solution Approach 1:
The patent replaces mechanical dispersion methods (physical agitation, ultrasonic dispersion) with electrostatic field-based electrospraying technology. The electrospraying process uses electrical forces to disperse inorganic particles uniformly in the coating layer, preventing agglomeration during drying that occurs with mechanical methods. This substitution of mechanical system with electrical field system resolves the contradiction between initial dispersion and prevention of agglomeration.
Solution Approach 2:
The patent changes the dispersion mechanism from mechanical force to electrical force by applying high voltage during the coating process. This parameter change in the dispersion mechanism allows particles to remain uniformly dispersed throughout the drying process, preventing agglomeration and ensuring reliable short circuit prevention functionality.
2Reliability
If a porous coating layer with excessive amount of inorganic particles is formed to prevent short circuit, then thermal stability is improved, but uniform dispersion of particles becomes difficult to achieve
Solution Approach 1:
The patent replaces mechanical dispersion methods with electrospraying technology that uses electrical forces to achieve uniform particle distribution. This allows excessive amounts of inorganic particles to be uniformly dispersed throughout the coating layer without agglomeration, simultaneously achieving both short circuit prevention and uniform pore distribution.
Solution Approach 2:
The patent changes the coating application method to electrospraying, which fundamentally alters how particles are distributed in the coating. This parameter change enables uniform dispersion of excessive inorganic particle amounts, resolving the contradiction between achieving sufficient particle content for safety and maintaining uniform distribution for manufacturing quality.
3Ease of manufacture
If polyolefin-based porous substrate is used as separator, then electrochemical devices can be manufactured, but thermal shrinking occurs at 100°C or above causing short circuit
Solution Approach 1:
The patent creates a composite coating layer combining binder polymer with excessive amounts of heat-resistant inorganic particles. This composite structure provides both the manufacturability of polymer-based materials and the thermal stability of inorganic particles, preventing thermal shrinking at high temperatures while maintaining ease of manufacture.
Solution Approach 2:
The patent introduces a porous coating layer as an intermediary between the polyolefin separator and the electrode active material layers. This intermediate layer acts as a thermal barrier that prevents short circuit during thermal runaway, allowing the use of easily manufactured polyolefin substrates while achieving high thermal stability through the inorganic particle-containing coating.
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 method results in a porous, non-woven fabric coating layer with uniformly dispersed pores, enhancing the thermal stability and preventing short circuits between the anode and cathode, thus improving the performance and safety of electrochemical devices.
Implementation Method 1
electroemitting the sol solution onto an outer surface of an electrode active material layer
Implementation Method 2
subsequent thermal treatment to create a uniformly dispersed, high-thermal-stability coating layer
Data Source
Figure 1~2
Figure 3~4
AI summary
A method for manufacturing an electrode may include (S1) preparing a sol solution containing a metal alkoxide compound, and (S2) forming a porous non-woven coating layer of an inorganic fiber by electroemitting the sol solution onto an outer surface of an electrode active material layer formed on at least one surface of a current collector. The porous non-woven coating layer formed on the outer surface of the electrode active material layer may be made from an inorganic fiber having excellent thermal stability. When an electrochemical device is overheated, the porous non-woven coating layer may contribute to suppression of a short circuit between a cathode and an anode and performance improvement of an electrochemical device due to uniform distribution of pores.