Intermittent Dry Electrode Coating for Burr-Free Lithium Batteries
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Solution Overview
Problem
The challenge is to develop a method for manufacturing lithium batteries with higher energy density and smaller size, while reducing the use of solvents in the electrode manufacturing process, as existing methods involving solvent-based slurries are inefficient and lead to defects like burrs and recesses, affecting the battery's cycling performance.
Innovation Solution
A dry electrode manufacturing method is introduced, where a metal layer and a dry electrode film are intermittently coated at varying speeds, allowing the film to be applied only during specific speeds, eliminating the need for solvent-based processes and reducing defects, and utilizing a device with laminator rolls to control the coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based slurry is used for electrode manufacturing, then the coating process can be simplified, but excessive solvent is used leading to defects like burrs and recesses
Solution Approach 1:
The patent changes the physical state parameter of the electrode material from liquid slurry (requiring solvent) to solid film form. This parameter change eliminates the need for solvent-based processes while maintaining coating capability, thereby resolving the contradiction between manufacturing simplicity and surface quality.
Solution Approach 2:
The patent extracts and removes the solvent component from the traditional slurry-based electrode manufacturing process. By using a dry film formation method, the harmful solvent is completely eliminated, preventing the formation of burrs and recesses while maintaining process efficiency.
2Productivity
If continuous coating is used, then manufacturing speed is high, but defects like burrs and recesses occur due to solvent evaporation issues
Solution Approach 1:
The patent employs periodic intermittent coating action where the coating process is applied in cycles rather than continuously. This periodic application allows proper setting and bonding of each layer before the next is applied, preventing defects while maintaining high manufacturing speed through efficient cycle optimization.
3Ease of manufacture
If solvent-based processes are used, then electrode materials can be easily coated, but side reactions occur affecting cycling performance
Solution Approach 1:
The patent creates an inert environment by completely eliminating solvent-based processes. The dry film formation method prevents solvent-related side reactions and chemical contamination, thereby improving battery cycling performance while maintaining coating ease through the simplified dry process.
4Volume of moving object
If high energy density batteries are manufactured, then battery size can be reduced, but manufacturing complexity increases
Solution Approach 1:
The patent implements continuous dry film formation and winding processes that eliminate intermediate drying and curing steps required in traditional methods. This continuous action maintains high manufacturing simplicity while enabling high energy density batteries through precise material deposition and reduced waste.
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 simplifies the electrode manufacturing process, reduces defects, and improves the cycling performance of lithium batteries by ensuring uniform coating and minimizing side reactions, leading to enhanced energy density and smaller battery sizes.
Implementation Method 1
a first laminator roll and a second laminator roll, spaced from each other... forming a dry electrode active material layer by intermittently applying the dry electrode film onto at least one side of the metal layer
Data Source
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AI summary
A method of preparing a dry electrode, a device for manufacturing a dry electrode, a dry electrode, and a lithium battery are provided. The method includes supplying a metal layer at a first speed, supplying a dry electrode film at a second speed while supplying the dry electrode film intermittently at a third speed less than the second speed, and forming a dry electrode active material layer by intermittently disposing the dry electrode film on at least one side (e.g., one side or both opposite sides) of the metal layer, wherein the dry electrode film is disposed on the metal layer while the dry electrode film is being supplied at the second speed, and the dry electrode film is not disposed on the metal layer while the dry electrode film is being supplied at the third speed.