Non-aqueous Electrode Manufacturing Without Drying
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Solution Overview
Problem
Current methods for manufacturing non-aqueous electrolyte secondary battery electrode sheets require a drying step and include thickening agents, which increase production time and costs while limiting bonding strength and resistance.
Innovation Solution
A method involving applying a binder solution to a current collector foil, followed by active material particles and additional binder solution, then pressing, without the need for a drying step or thickening agents, to create a bonded layer with enhanced bonding strength and reduced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mixture paste containing thickening agents is applied to the current collector, then the electrode sheet can be formed with adequate viscosity and structure, but the resistance increases and manufacturing time is extended due to drying requirements
Solution Approach 1:
The invention extracts and eliminates the thickening agent from the traditional paste mixture, using only binder and active material particles. This removal of the thickening agent component allows the electrode to be formed without requiring a drying step, thereby reducing manufacturing time while maintaining adequate electrode formation quality through the binder's adhesive properties
Solution Approach 2:
The invention changes the composition parameters of the applied mixture by eliminating the thickening agent and adjusting the binder-to-active material ratio. This parameter change transforms the mixture from a paste requiring drying to a binder-based composition that can be directly pressed into place, reducing both manufacturing time and resistance
2Stability of the object's composition
If a mixture paste with thickening agents is used, then the electrode structure can be maintained, but the resistance of the electrode and battery increases
Solution Approach 1:
The invention extracts and removes the thickening agent from the traditional paste composition, retaining only the binder and active material particles. This elimination of the thickening agent directly reduces electrode resistance while the binder maintains the structural stability of the electrode through its adhesive bonding between particles
Solution Approach 2:
The invention uses a composite material approach by optimizing the binder-active material composition ratio to create a structure that provides both stability and low resistance. The binder forms a conductive network that maintains structural integrity while minimizing resistive losses compared to traditional thickening agent-based pastes
3Strength
If traditional paste coating method is used, then adequate bonding can be achieved, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The invention extracts and eliminates the thickening agent component from the traditional paste formulation, simplifying the material composition to binder and active material only. This simplification reduces manufacturing process complexity and costs while the optimized binder composition maintains adequate bonding strength between the electrode layer and current collector
Solution Approach 2:
The invention changes the compositional parameters by eliminating the thickening agent and optimizing the binder concentration and type. This parameter change simplifies the manufacturing process by removing the drying step and reduces material costs, while the enhanced binder formulation maintains or improves bonding strength
4Manufacturing precision
If a drying step is included in the manufacturing process, then the electrode structure can be properly formed, but productivity decreases
Solution Approach 1:
The invention extracts and removes the drying step from the manufacturing process by eliminating the thickening agent that would otherwise require drying. The binder-based composition can be directly pressed into place without drying, thereby improving productivity while the pressing step ensures proper electrode structure formation
Solution Approach 2:
The invention skips the time-consuming drying step entirely by using a binder-based composition that does not require moisture removal. The process rushes through to the pressing step directly, improving productivity while the pressing operation ensures adequate electrode structure formation and bonding
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 results in lower resistance electrode sheets and batteries, reduced manufacturing time, and lower costs, with improved bonding between active material particles and the current collector.
Implementation Method 1
a binder solution is applied to a current collector foil... supplying the binder solution onto the active material particles... pressing a layer of the active material particles on the current collector foil
Data Source
AI summary
A method of manufacturing a non-aqueous electrolyte secondary battery proposed herein includes a first binder supplying step (101), an active material supplying step (102), a second binder supplying step (103), and a pressing step (105). The first binder supplying step (101) is a step of applying a binder solution (122) to a current collector foil (121). The active material supplying step (102) is a step of supplying active material particles (123) onto the current collector foil (121) coated with the binder solution (122). The second binder supplying step (103) is a step of supplying the binder solution (122) onto the active material particles (123). The pressing step (105) is a step of pressing a layer of the active material particles (123) on the current collector foil (121).