Coated Electrode Stamping With Oscillation for Solvent-Free Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing battery electrodes are challenging due to the use of solvents, which require extensive safety measures, increase manufacturing costs, and contribute to environmental concerns.
Innovation Solution
A solvent-free method for preparing coated electrodes using a stamp with a chamber filled with a coating material, where the stamp is pressed onto a substrate while applying an oscillating movement, eliminating the need for solvents and associated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If solvent-based coating process is used, then homogeneous slurry can be achieved, but safety risks and manufacturing costs increase due to flammability and toxicity
Solution Approach 1:
The patent extracts and eliminates the solvent component from the traditional slurry coating process, transitioning to a dry powder coating method. This removes the harmful flammable and toxic elements while maintaining coating functionality through direct application of active material, conductive additive, and binder in powder form.
Solution Approach 2:
The patent changes the physical state parameter of the coating materials from liquid/slurry to dry powder form. This fundamental parameter change eliminates solvent-related safety issues while achieving effective coating through controlled powder application and compression.
2Ease of manufacture
If solvent-based coating process is used, then coating can be applied, but manufacturing costs and equipment complexity increase due to handling, storage, and disposal requirements
Solution Approach 1:
The patent removes the solvent handling infrastructure from the manufacturing process, eliminating the need for specialized storage tanks, ventilation systems, fire safety equipment, and waste treatment facilities associated with solvent management.
Solution Approach 2:
The patent converts the traditional disadvantage of dry powder coating (poor adhesion and homogeneity) into an advantage by using compression forces and optional heating to achieve excellent coating density and adhesion without solvent mediation, thereby simplifying the overall manufacturing system.
3Ease of manufacture
If solvent-based coating process is used, then coating can be formed, but energy consumption and space requirements increase due to drying and processing needs
Solution Approach 1:
The patent extracts and eliminates the drying step from the coating process by using dry powder materials that do not require solvent evaporation. The coating is formed directly through compression and optional low-temperature heating, significantly reducing energy consumption.
Solution Approach 2:
The patent enables continuous coating production by applying compression forces during the coating process itself, eliminating the separate drying step required in solvent-based methods. This continuous action improves productivity while reducing total energy input.
4Length of moving object
If multiple calendering stages are used to obtain thin free-standing film, then film thickness is reduced, but manufacturing line size and cost increase
Solution Approach 1:
The patent segments the coating formation process into direct application and compression steps, eliminating the need for multiple calendering stages. The stamp or roller applies coating material directly to the substrate and compresses it in a single integrated action, achieving thin uniform coatings without complex multi-stage equipment.
Solution Approach 2:
The patent replaces the complex mechanical calendering system with a simpler compression-based coating method. Instead of passing the coating through multiple rollers under varying pressures, a single stamp or roller applies controlled compression directly to the coating, achieving the desired thickness and density.
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 reduces waste and energy consumption, eliminates the need for drying or calendaring, and allows for a compact, cost-effective, and reliable production process, resulting in high-quality coated electrodes.
Implementation Method 1
forming a coating layer on the substrate by pressing the stamp onto the substrate while an oscillating movement is applied to the stamp
Implementation Method 2
pressing the stamp onto the substrate while an oscillating movement is applied to the stamp
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
The invention relates to a method (100) of preparing a coated electrode (250, 400), the method (100) comprising: providing a stamp (205) with a chamber (210), wherein the chamber (210) is filled with a coating material (215); providing a substrate (220), and forming a coating layer (230, 405) on the substrate (220) by pressing the stamp (205) onto the substrate (220) while an oscillating movement is applied to the stamp (205).