Multi-Layer Secondary Battery Electrode Porosity Control
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Solution Overview
Problem
Existing methods for manufacturing multi-layer electrodes for secondary batteries struggle to adjust porosity effectively, which is crucial for securing Li ion conductivity, particularly when using the ESD method with multiple spray devices.
Innovation Solution
A method involving the sequential spraying of suspension liquids onto a base material or existing electrode layers at predetermined surface temperatures to form electrode layers with varying porosities, allowing for the adjustment of porosity in each layer by controlling the temperature and composition of the suspension liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sequential spray coating is carried out using multiple spray devices to form multi-layer electrode, then electrode structure complexity is improved, but porosity control precision deteriorates
Solution Approach 1:
The patent applies local quality by controlling the surface temperature of each electrode layer differently during the spraying process. Each layer receives a specific temperature treatment tailored to its requirements, enabling independent porosity control for each layer while maintaining the multi-layer structure. This resolves the contradiction by making each layer have localized temperature properties that control its specific porosity characteristics.
Solution Approach 2:
The patent changes the temperature parameter of the surface on which suspension liquid is sprayed to control porosity. By adjusting the surface temperature as a key parameter, the invention enables precise control over the porosity of each electrode layer independently, thereby resolving the porosity control precision issue while maintaining the multi-layer structure complexity.
2Manufacturing precision
If surface temperature is adjusted for each electrode layer during spraying, then porosity adjustment precision is improved, but process complexity increases
Solution Approach 1:
The patent applies preliminary action by adjusting the surface temperature of each electrode layer before spraying the suspension liquid onto it. By pre-controlling the temperature condition, the process simplifies the overall complexity because the temperature is set in advance rather than requiring complex real-time control during spraying, thus improving porosity adjustment precision while managing process complexity.
3Reliability
If different suspension liquids are sprayed at different temperatures, then Li ion conductivity is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent applies local quality by giving different temperature conditions to different suspension liquids based on their specific requirements for Li ion conductivity. Each suspension liquid is sprayed at a temperature optimized for its properties, enabling improved Li ion conductivity for each layer while managing the overall process complexity through localized optimization rather than uniform treatment.
Solution Approach 2:
The patent changes the temperature parameter for each suspension liquid spraying operation to optimize Li ion conductivity. By adjusting temperature as a controllable parameter for each layer, the invention achieves improved reliability in terms of Li ion conductivity while the systematic approach to parameter control helps manage manufacturing process complexity.
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 enables the lamination of electrode layers with distinct porosities, enhancing Li ion conductivity and energy density while allowing for precise control over material composition and void size, thereby improving the electrode's performance.
Implementation Method 1
a method of manufacturing a multi-layer electrode used for a secondary battery, and includes a process of sequentially spraying suspension liquid that contains an active material onto a base material to form two or more electrode layers
Implementation Method 2
spraying a first suspension liquid onto the base material or an existing electrode layer provided on the side of the base material having a predetermined surface temperature to form a primary electrode layer
Data Source
AI summary
The present invention aims to provide a multi-layer electrode. A method of manufacturing the multi-layer electrode according to the present invention is used in a secondary battery. The manufacturing method includes a process of sequentially spraying suspension liquid 51 to 54 that contain an active material onto a base material 50 to form two, three, four or more electrode layers 56 to 59. The process of forming the electrode layers 56 to 59 includes a process of spraying suspension liquid onto the base material 50 having a predetermined surface temperature to form an electrode layer 56 and a process of spraying suspension liquid onto the electrode layer 56 or another electrode layer having a surface temperature different from the predetermined surface temperature to form an electrode layer that is more distal than the electrode layer 56 with respect to the base material 50.