Patterned Adhesion Layer for Secondary Battery Ion Transfer
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Solution Overview
Problem
Conventional methods for coating binder materials on separators in lithium secondary batteries hinder lithium ion transfer due to the adhesion layer's obstruction, leading to inefficiencies in ion transport and increased manufacturing costs.
Innovation Solution
A method involving a polydimethylsiloxane mold with a concavo-convex pattern is used to create an adhesion layer with a regular, vertically open cavity structure, minimizing the surface area and size of the adhesion layer, thereby improving lithium ion transfer and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If binder material is coated over the entire separator surface to improve adhesion with electrodes, then adhesive strength is improved, but lithium ion transfer is hindered
Solution Approach 1:
The separator surface is divided into adhesive regions and non-adhesive regions. The adhesive layer is segmented into discrete patterns (such as dots, lines, or geometric shapes) rather than continuous coating. This segmentation allows lithium ions to pass through non-adhesive regions while maintaining electrode attachment at segmented adhesive points, thus resolving the contradiction between adhesion strength and ion transfer efficiency.
Solution Approach 2:
Different regions of the separator are given different properties: some regions have adhesive coating for electrode attachment, while other regions remain non-adhesive to facilitate lithium ion transfer. This local differentiation of surface properties allows the separator to simultaneously achieve both strong adhesion where needed and high ion conductivity where required, resolving the technical contradiction.
2Strength
If conventional coating techniques are used to coat binder material on separator, then adhesive properties are improved, but manufacturing complexity and cost increase
Solution Approach 1:
A mold with pre-formed patterns (containing both adhesive and non-adhesive regions) is prepared in advance. The adhesive slurry is then applied to this pre-patterned mold, which automatically transfers the patterned adhesive structure onto the separator. This preliminary preparation of the mold simplifies the manufacturing process compared to conventional techniques that require complex masking and multiple coating steps, while still achieving the desired patterned adhesive structure.
Solution Approach 2:
The patterned adhesive structure is created by copying the mold's surface pattern onto the separator. The mold serves as a template that replicates the desired adhesive/non-adhesive pattern directly onto the separator surface through simple contact and material transfer, avoiding the need for complex direct patterning techniques and reducing manufacturing 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 enhances lithium ion transfer efficiency and reduces manufacturing costs by minimizing the adhesion layer's surface area, leading to improved battery performance and cost savings.
Implementation Method 1
transferred a pattern of a mold to a separator or an electrode to form an adhesion layer having cavities open vertically
Data Source
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AI summary
The present disclosure improves a quality of the secondary battery by minimizing a size of the adhesion layer between the electrode and the separator to improve the transfer of lithium ions of which movement was obstructed by the adhesion layer.