Fibrillable Binder Particles for Dry Electrode Manufacturing
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Solution Overview
Problem
The conventional manufacturing method for electrochemical device electrodes is time-consuming and costly, limiting mass productivity due to multiple process steps and high energy requirements.
Innovation Solution
A binder in the form of secondary particles is used, which can be separated into first particles through stirring at specific speeds, allowing for a simplified electrode manufacturing process by mixing active and conductive materials with the binder without additional pulverization, thereby reducing process time and cost while enhancing dispersion and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional film forming process is used with bulk active material and non-fibrillable binder mixed in high shear, then electrode can be manufactured, but manufacturing process becomes complex and time-consuming with poor mass productivity
Solution Approach 1:
The binder is segmented into fibrillable particles that can be separated into individual fibrils during mixing, creating a distributed network structure throughout the electrode. This segmentation allows the binder to function effectively at lower concentrations while simplifying the manufacturing process and improving productivity.
Solution Approach 2:
The invention changes the particle size parameter of the binder from bulk material to fibrillable particles with specific size ranges (D10: 1-10 μm, D50: 10-30 μm, D90: 30-50 μm). This parameter change enables the binder to fibrillate during mixing, simplifying the manufacturing process and improving mass productivity.
2Manufacturing precision
If conventional manufacturing process with multiple process steps is used, then electrode can be produced, but production time and cost increase significantly
Solution Approach 1:
The invention merges multiple manufacturing steps into a single mixing process. The fibrillable binder particles are mixed with active material and conductive filler in one step, and the binder automatically fibrillates during mixing, eliminating the need for separate pulverization and film forming steps. This reduces production time while maintaining manufacturing precision through controlled particle size distribution.
3Stability of the object's composition
If high shear mixing is used to mix active material and binder, then composition can be prepared, but energy consumption and process complexity increase
Solution Approach 1:
The invention uses fibrillable binder particles that are consumed during the mixing process to create a distributed fibril network. These particles are designed to break down into fibrils during mixing, providing binding function without requiring continuous high shear energy input. This reduces energy consumption while maintaining composition stability.
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 approach simplifies the electrode manufacturing process, reduces production time and cost, and improves mass productivity by ensuring excellent dispersion and conductivity of the dry electrode, suppressing agglomeration and enhancing adhesion to the current collector.
Implementation Method 1
the shear force applied to the binder may be greater than or equal to the binder's own energy, and may be less than the plastic deformation energy of the binder
Data Source
AI summary
The present embodiments relate to a binder, a composition for manufacturing a dry electrode comprising the same, and a method for manufacturing a dry electrode. In one embodiment, as secondary particles comprising at least one first particle, the binder may be separated from the secondary particles into the at least one first particle when stirred with a dispersion equipment.