Fibrillated Fluffy Powder Processing for Low-Energy Electrode Fibrillation
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Solution Overview
Problem
Existing dry-process electrode technologies for lithium-ion batteries face challenges in achieving sufficient fibrillation of dry-process electrode powder, leading to high energy consumption, device wear, and potential damage to active materials, which affects the electrochemical performance of lithium-ion batteries.
Innovation Solution
A method of manufacturing fibrillated fluffy powder involves a series of mixings with specific binders and heating, which improves fibrillation and reduces device requirements, resulting in better film-forming performance and strength of the fibrillated fluffy powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high rotation speeds are used for material and airflow mixing to achieve fibrillation, then fibrillation effect is improved, but device wear and energy consumption increase significantly
Solution Approach 1:
The patent changes the mixing parameters by using low rotation speeds (100-500 rpm for first mixer, 500-1000 rpm for second mixer) compared to conventional high-speed mixing, while achieving sufficient fibrillation through extended mixing time and multi-stage process with controlled parameter progression
Solution Approach 2:
The patent divides the mixing process into multiple stages with different mixers and speed levels: first mixing (100-500 rpm), second mixing (500-1000 rpm), and third mixing, allowing gradual fibrillation without requiring excessive speed in any single stage
2Manufacturing precision
If high rotation speeds are used for material and airflow mixing to achieve fibrillation, then fibrillation effect is improved, but device wear increases
Solution Approach 1:
The patent uses low rotation speeds (100-1000 rpm range) throughout the mixing process, significantly reducing mechanical stress and wear on mixing devices while achieving fibrillation through extended processing time and multi-stage approach
Solution Approach 2:
The patent performs preliminary binding before mixing by adding binders to the powder mixture, which facilitates fibrillation without requiring high-speed mechanical shearing, thereby reducing device wear
3Ease of manufacture
If slightly lower shearing strength is used to reduce device wear, then device wear is reduced, but sufficient fibrillation cannot be achieved
Solution Approach 1:
The patent segments the fibrillation process into multiple mixing stages with progressively increasing intensity, allowing cumulative fibrillation effect to reach sufficient levels without requiring high shearing strength in any single stage
Solution Approach 2:
The patent maintains continuous mixing action across multiple stages and extendes mixing time, ensuring that fibrillation accumulates progressively without interruption, achieving sufficient effect through sustained lower-intensity action rather than brief high-intensity action
4Manufacturing precision
If high rotation speeds are used for mixing, then fibrillation is improved, but electrochemical performance of active material is affected due to structural damage
Solution Approach 1:
The patent uses low rotation speeds (100-1000 rpm) that generate gentle shearing forces, preventing structural damage to active material particles while still achieving sufficient fibrillation through extended mixing time and multi-stage process
Solution Approach 2:
The patent adds binders before mixing to create a preliminary bound structure that facilitates fibrillation through gentle mechanical action, protecting active material structure from damage that would occur with high-speed mixing
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 enhances the fibrillation of the powder, improving film-forming performance and strength, while reducing device wear and energy consumption, thus addressing the limitations of existing technologies.
Implementation Method 1
a mixing device is used to perform mixing on the mixture, so as to obtain the fibrillated fluffy powder
Implementation Method 2
a heating device is used to perform heating on the mixed powder, so as to obtain the fibrillated fluffy powder
Data Source
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AI summary
A method of manufacturing fibrillated fluffy powder includes: performing (S 110) a first mixing to mix an active material and a conductive agent to obtain a first mixture; adding (S120) a first binder to the first mixture, performing a second mixing on the first binder and the first mixture to obtain a second mixture; adding (S130) a second binder solution to the second mixture, performing a third mixing on the second binder solution and the second mixture to obtain a third mixture; and performing (S140) a fourth mixing on the third mixture, heating the mixed third mixture to obtain the fibrillated fluffy powder.