Multilayer Electrode Films for Adhesion and Power-Capacity Balance
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Solution Overview
Problem
Existing electrode films in energy storage devices face mechanical limitations due to poor adhesion between active layers and current collectors, and cohesion between active materials and binders, leading to reduced performance in power delivery and energy storage capacity, with conventional fabrication methods imposing practical limits on structural properties and requiring expensive drying steps.
Innovation Solution
The development of multilayer electrode films comprising two or more self-supporting active layers with different compositions, which are stacked and laminated to a current collector without a separate adhesive layer, allowing for improved adhesion and cohesion, and enabling the combination of active layers with specific properties to enhance energy and power performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fabrication methods are used to create single-layer electrode films, then the manufacturing process is simple, but the adhesion between active layers and current collectors is poor and mechanical properties are limited
Solution Approach 1:
The electrode film is divided into multiple separate active layers (first active layer, second active layer, etc.) that are stacked and adhered together. Each layer can be independently fabricated with optimized composition and properties, then combined to form the complete electrode film with enhanced mechanical strength and adhesion characteristics.
Solution Approach 2:
The electrode film uses composite construction with multiple active layers having different compositions (e.g., different active materials or binder ratios) stacked together. This composite structure allows each layer to contribute specific mechanical or electrochemical properties, resulting in overall enhanced performance that cannot be achieved with a single homogeneous layer.
2Strength
If adhesive layers are added between active layers to improve adhesion, then bonding strength increases, but device complexity and manufacturing cost increase
Solution Approach 1:
The separate adhesive layer is removed from the structure. Instead of adding an adhesive between active layers, the active layers themselves are designed with intrinsic adhesion capabilities through their composition (e.g., binder materials) and fabrication method (e.g., hot pressing), eliminating the need for additional adhesive components and simplifying the overall structure.
Solution Approach 2:
The active layers are designed to adhere to each other through their own inherent properties (such as binder materials within the active layer composition) rather than requiring a separate adhesive agent. The hot pressing process enables the layers to bond to each other directly, making the system self-sufficient for adhesion without external adhesive assistance.
3Manufacturing precision
If expensive drying steps are used in conventional fabrication, then electrode film quality is improved, but manufacturing cost increases
Solution Approach 1:
The conventional thermal drying process is replaced with a hot pressing mechanism. Instead of using heat and time to evaporate solvents slowly, the hot press applies controlled heat and pressure simultaneously to rapidly remove solvents and densify the electrode film structure in a single step, reducing both energy consumption and manufacturing time.
Solution Approach 2:
The fabrication process changes the parameters of heat application by using high temperature and high pressure conditions during hot pressing, rather than low temperature and long duration drying. This parameter change enables rapid solvent removal and film formation that achieves high quality electrodes with reduced energy input and shorter processing time.
Data Source
AI summary
Provided herein are energy storage device electrode films comprising multiple active layers, and methods of forming such multiple active layer energy storage device electrode films. Each active layer may be a self-supporting active layer comprising a binder and an active material. The binder and/or active material may be the same or different as any other active layer. The active layers may be stacked to form an electrode film, and the electrode film may be laminated with a current collector to form an electrode.