Electrode Plate Manufacturing via Wet-on-Wet Slurry Coating
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Solution Overview
Problem
Existing electrode plates for secondary batteries have high resistance, which limits their power characteristics, and current methods for reducing resistance are insufficient in achieving optimal performance.
Innovation Solution
A method for manufacturing an electrode plate involving the application of a conductive layer slurry with fibrous carbon to a metal foil core, followed by the application of an active material mix layer slurry before the conductive layer dries, allowing for interdiffusion and the formation of a diffusion layer with increased contact area, thereby reducing contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive layer is formed on the core surface before applying the active material mix layer, then the contact resistance between core and active material mix layer is reduced, but the manufacturing process complexity increases
Solution Approach 1:
The patent combines the conductive layer application and active material mix layer application into a single simultaneous coating step, eliminating the need for separate drying and application steps while achieving both conductive layer formation and active material layer formation in one process
Solution Approach 2:
The conductive layer is prepared in advance as part of the coating slurry composition, allowing it to be applied together with the active material mix layer in a single step, thus preparing the conductive interface before the active material layer is fully formed
2Shape
If the conductive layer slurry is dried before applying the active material mix layer slurry, then the layer structure is well-defined, but the contact area between fibrous carbon and active material is reduced
Solution Approach 1:
The active material mix layer slurry is applied to the conductive layer slurry before the conductive layer slurry dries, allowing the fibrous carbon to be trapped within the active material layer while maintaining a defined layered structure after drying
Solution Approach 2:
The patent controls the drying process parameters to achieve optimal moisture removal while preserving the interdiffused structure, where the fibrous carbon becomes embedded in the active material matrix during the drying phase
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 an electrode plate with lower resistance and improved power characteristics for secondary batteries, enhancing their performance in applications such as electric vehicles.
Implementation Method 1
Interdiffusion occurs at the interface between a layer of the conductive layer slurry and a layer of the positive electrode active material mix layer slurry, that is, the fibrous carbon contained in the conductive layer slurry diffuses into the active material mix layer slurry and the active material contained in the active material mix layer slurry diffuses into the conductive layer slurry
Implementation Method 2
The conductive layer slurry and the positive electrode active material mix layer slurry are dried, thereby a conductive layer and a positive electrode active material mix layer are formed on the positive electrode core
Data Source
AI summary
A method for manufacturing an electrode plate includes a first application step of applying conductive layer slurry containing fibrous carbon to a surface of a core made of metal foil, a second application step of applying active material mix layer slurry containing an active material to the conductive layer slurry before the conductive layer slurry dries, and a drying step of drying the conductive layer slurry and the active material mix layer slurry. The fibrous carbon contained in the conductive layer slurry has a fiber length-to-diameter ratio of 20:1 to 2,000:1. The amount of the fibrous carbon, contained in the conductive layer slurry applied to the core surface, per unit are of the core is 0.05 g/m2 to 0.20 g/m2 after the first application step.