Patterned Conductive Coating for Dry Electrode Adhesion
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Solution Overview
Problem
Existing solvent-free dry electrode fabrication methods face challenges with low surface energy binders like PTFE, leading to suboptimal adhesion with current collectors, which can increase internal resistance and reduce battery performance and longevity.
Innovation Solution
The use of embossed conductive dots on a current collector, formed from a mix of conductive particles and binders, enhances the adhesion of the electrode active layer to the collector. This is achieved through a patterned embossing technique, where the conductive dots are laminated with a solvent-free, self-supporting electrode film containing fibrilized polymeric binders like polytetrafluoroethylene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-free dry electrode fabrication methods are used, then environmental friendliness and process simplification are improved, but adhesion between electrode active layer and current collector deteriorates due to low surface energy binders like PTFE
Solution Approach 1:
The current collector surface is segmented into multiple micro-dots distributed across the surface. Each dot acts as an independent adhesion point, collectively providing strong bonding between the electrode active layer and current collector while maintaining the solvent-free fabrication process.
Solution Approach 2:
The embossed conductive dots create localized regions with different surface properties on the current collector. These localized structures provide enhanced adhesion points specifically where needed, while the rest of the current collector maintains its original properties. The dots concentrate the adhesion function in specific locations rather than requiring uniform surface modification.
2Object-affected harmful factors
If PTFE binder is used in solvent-free electrodes, then environmental safety is improved by eliminating solvents, but electrical conductivity deteriorates due to low surface energy properties
Solution Approach 1:
The conductive dots are formed as composite structures containing both PTFE binder and conductive particles (such as carbon black or metal particles). The PTFE provides structural integrity and solvent-free bonding, while the conductive particles embedded within provide electrical conductivity pathways, creating a composite material that combines the advantages of both components.
Solution Approach 2:
The conductive particles act as intermediaries between the low-surface-energy PTFE binder and the electrode active layer. These particles provide conductive pathways that bridge the PTFE dots and the active material, enabling electrical conductivity even though the PTFE itself has low surface energy and poor conductivity.
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
The enhanced adhesion between the electrode active layer and the current collector improves the electrical conductivity and mechanical stability of the electrode, leading to increased battery performance and extended longevity.
Implementation Method 1
The conductive dots comprise an agglomeration of conductive particles and binder... enhances the adhesion of the electrode active layer to the collector
Implementation Method 2
The use of embossed conductive dots on a current collector... enhances the adhesion of the electrode active layer to the collector
Implementation Method 3
The conductive particles used in the electrode may be carbon based... The enhanced adhesion between the electrode active layer and the current collector improves the electrical conductivity
Data Source
AI summary
An electrode includes a current collector, a pattern of conductive dots, each including an agglomeration of conductive particles and binder, embossed on the current collector, and a self-supporting solvent-free electrode film, including conductive particles, fibrilized polymeric binder, and active material, laminated onto the conductive dots and current collector.