Patterned Freestanding Film Electrodes for Dry Battery Adhesion
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Solution Overview
Problem
Conventional secondary battery electrodes require high-temperature heat treatment, which can damage metal oxides and lack dry manufacturing methods, necessitating the development of electrodes with improved peel strength and adhesive force.
Innovation Solution
A freestanding film with a directional concave-convex pattern is used for the electrode, where the pattern has an interval of 100 μm to 2000 μm and a depth of 1.5 μm to 35 μm, enhancing adhesive force and peel strength by dry-mixing active materials, conductive materials, and a binder, and attaching the film to an electrode current collector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional wet manufacturing method is used for secondary battery electrodes, then the electrode can be manufactured, but high-temperature heat treatment is required which may damage metal oxide and reduces manufacturing safety
Solution Approach 1:
The invention changes the manufacturing method from wet to dry process, fundamentally altering the processing parameters to eliminate high-temperature heat treatment requirements. The dry-manufactured freestanding film can be directly attached to current collectors without thermal processing, preserving metal oxide structure and enabling safer manufacturing
Solution Approach 2:
The invention replaces the thermal bonding mechanism (heat treatment) with a mechanical attachment system. The freestanding film is directly attached to the current collector through physical adhesion or mechanical bonding, eliminating the need for high-temperature processing while maintaining structural integrity
2Reliability
If a dry manufacturing method is used for secondary battery electrodes, then high-temperature heat treatment is avoided, but the adhesive force and peel strength need to be improved
Solution Approach 1:
The invention applies local quality enhancement by creating a patterned surface structure on the freestanding film with specific concave-convex features. This localized structural modification at the attachment interface increases surface area and mechanical interlocking, thereby improving adhesive force without requiring high-temperature treatment
Solution Approach 2:
The invention uses composite material structure combining the freestanding film with patterned surface features and binder materials. The combination of these materials with optimized composition and structure achieves strong adhesion to current collectors while maintaining compatibility with dry manufacturing processes
3Ease of manufacture
If binder content is reduced in the electrode, then the dry manufacturing process is enabled, but the peel strength must be maintained within prescribed limits
Solution Approach 1:
The invention optimizes the binder content parameter to a specific range that enables dry manufacturing while maintaining adequate peel strength. By precisely controlling the binder composition and quantity, the invention achieves the balance between manufacturability and mechanical performance
Solution Approach 2:
The invention uses composite material formulation combining active material, conductive material, and binder in optimized ratios. This composite structure allows the electrode to maintain structural integrity and required peel strength with minimal binder content, enabling dry manufacturing processes
Data Source
AI summary
The freestanding film according to one embodiment of the present disclosure includes a pattern having directionality on at least one surface and has improved peel strength and adhesive force. Further provided is an electrode for secondary battery including the freestanding film in an electrode layer, a secondary battery including the same, and a method of manufacturing the electrode.