Electrode Active Material Layer Transfer to Perforated Current Collector
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming electrode active material layers on perforated collectors, such as punching metal and expanded metal, face challenges in achieving uniform thickness and adhesion, leading to variations in electrode performance and increased production complexity.
Innovation Solution
A method involving the formation of an electrode active material layer on a base material, followed by lamination and bonding to the collector using a hot press, allows for uniform and high-adhesive coating, particularly suitable for perforated collectors, using a thermoplastic resin film with a release treatment to facilitate easy transfer and peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If slurry is coated directly on perforated collector using twin-blade method, then electrode active material layers are formed on both sides of collector, but uniform thickness cannot be achieved and equipment complexity increases
Solution Approach 1:
The coating process is divided into two independent stages: first coating on a flat base material (achieving uniform thickness), then transferring to the perforated collector. This segmentation allows each stage to be optimized independently, avoiding the complexity of direct dual-side coating on the perforated collector.
Solution Approach 2:
A base material serves as an intermediary carrier for the electrode active material layer. The layer is first formed uniformly on the base material, then transferred to the perforated collector. This intermediary approach enables precise thickness control during coating while simplifying the overall equipment requirements.
2Ease of manufacture
If slurry is coated on rotating roller for perforated collector, then coating process is simplified, but uniform coating cannot be achieved due to slurry transfer
Solution Approach 1:
Instead of coating directly on the perforated collector (the traditional approach), the invention inverts the sequence by first coating on a flat base material and then transferring to the collector. This inversion eliminates the slurry transfer problem on rotating rollers while maintaining process simplicity.
3Productivity
If two dies and two sets of coating equipment are used for dual-side coating, then both sides of collector can be coated simultaneously, but equipment complexity and cost increase
Solution Approach 1:
The base material serves multiple functions: as a coating substrate, as a transfer medium, and as a temporary carrier. This multi-functionality allows a single coating equipment to produce dual-side coated electrodes by sequentially coating both sides of the base material, eliminating the need for two separate coating systems.
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 enables the production of electrodes with uniform thickness and improved adhesion, enhancing productivity and reducing production costs by using common equipment and minimizing the need for complex setups.
Implementation Method 1
laminating the electrode active material layer, formed on the surface of the base material, and a collector, followed by bonding the same by hot press
Data Source
AI summary
Disclosed is a method for manufacturing an electrode for an electrochemical element, that is capable of forming an electrode active material layer on a current collector, particularly a perforated current collector having through-holes extended from the obverse surface to the reverse surface thereof, such as a punching metal or an expanded metal, simply, evenly and with good adhesion. The method is characterized by comprising the steps of (1) forming an electrode active material layer on a surface of a base material by using an electrode composition containing an electrode active material, an electroconductive material, and a binder, (2) laminating a current collector on the electrode active material layer formed on the surface of the base material, followed by hot pressing to bond the electrode active material layer and the current collector to each other, and (3) separating the base material from the electrode active material layer.