Layered Battery Electrode Coating Without Slurry Intermixing
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Solution Overview
Problem
The existing methods for preparing secondary battery electrodes with a multi-layered structure are complex and prone to alignment errors and intermixing phenomena, requiring repetitive coating, drying, and rolling processes, which complicate the manufacturing process and increase the risk of layer detachment.
Innovation Solution
A method involving the use of a single coating device to apply slurries with different solvents and active materials, where the first slurry and second slurry are not mixed, forming distinct layers based on solvent polarity and density differences, allowing simultaneous coating and simplifying the process by preventing intermixing and alignment errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional multi-step coating and drying processes are used to form multi-layered electrodes, then layer structure can be achieved, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The patent combines multiple coating steps into a single coating process by using a coating device with multiple nozzles that can simultaneously apply different slurries to form multiple layers in one operation, eliminating the need for repetitive coating and drying cycles
Solution Approach 2:
The patent implements continuous multi-layer coating by maintaining the coating head in a fixed position while moving the substrate continuously, allowing multiple layers to be deposited in a single pass without stopping or repositioning, thereby simplifying the manufacturing process
2Manufacturing precision
If repetitive coating and drying steps are performed for each layer, then multi-layered structure can be formed, but manufacturing time increases
Solution Approach 1:
The patent merges multiple coating operations into a single continuous process where multiple slurries are coated simultaneously in one pass, eliminating repeated drying and re-coating cycles, thereby significantly reducing manufacturing time
Solution Approach 2:
The patent prepares multiple slurries with different solvents in advance, where the solvent properties are pre-configured to enable spontaneous layer formation during a single coating operation, avoiding the need for repeated processing steps
3Manufacturing precision
If multiple coating devices or sequential coating steps are used, then alignment precision can be maintained, but device complexity and process difficulty increase
Solution Approach 1:
The patent integrates multiple coating functions into a single coating device with multiple nozzles positioned at predetermined locations, allowing simultaneous coating of multiple layers with precise alignment without the complexity of multiple separate devices or sequential positioning operations
4Manufacturing precision
If slurries with different properties are coated sequentially, then multi-layered structure can be formed, but intermixing phenomenon occurs at layer interfaces
Solution Approach 1:
The patent changes the solvent parameters of the slurries, specifically using solvents with different polarities (polar solvent for first slurry, non-polar solvent for second slurry), which creates spontaneous phase separation at the interface during coating, preventing intermixing and maintaining clear layer boundaries
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 preparation of multi-layered electrodes by eliminating the need for repetitive coating and drying steps, minimizing alignment errors, and preventing intermixing, thereby reducing manufacturing complexity and time while ensuring efficient layer formation.
Implementation Method 1
the first solvent and the second solvent have mutually different physical properties, and form a layered structure of a first layer including the first slurry and a second layer including the second slurry on the current collector
Implementation Method 2
the first solvent and the second solvent have mutually different physical properties
Data Source
Figure 1~2
AI summary
A method of preparing an electrode for a secondary battery according to an embodiment of the present disclosure includes the steps of: injecting a first slurry prepared by dissolving a first active material in a first solvent and a second slurry prepared by dissolving a second active material in a second solvent into a single coating device; and coating the first slurry and the second slurry onto a current collector through the single coating device, wherein the first solvent and the second solvent have different physical properties, and form a layered structure of a first layer including the first slurry and a second layer including the second slurry on the current collector, respectively.