Porous Insulating Layer Coating on Wet Electrode Slurry
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Solution Overview
Problem
Conventional secondary cell electrode manufacturing processes face stability issues, particularly in lithium secondary cells with high energy density, leading to potential short circuits and thermal runaway due to inadequate heat resistance and pore blocking by binders in the porous insulating layer.
Innovation Solution
A method is introduced to coat a porous insulating layer with an inorganic compound powder or mixed powder on the electrode surface before the electrode layer slurry is dried, allowing simultaneous drying and preventing binder-induced pore blocking, thus enhancing structural stability and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the porous insulating layer is coated after the electrode layer slurry is dried, then the manufacturing process is simpler, but the binder blocks the pores causing stability issues
Solution Approach 1:
The porous insulating layer is coated on the electrode layer slurry before drying, performing the coating action in advance before the binder solidifies and blocks pores. This preliminary action prevents pore blocking while maintaining manufacturing simplicity.
Solution Approach 2:
The patent changes the physical state parameter of the electrode layer from dried to non-dried state during the coating process, allowing the porous insulating layer to be applied when the slurry is still in a workable state, preventing binder-induced pore blocking.
2Ease of operation
If the electrode layer slurry is dried before coating the porous insulating layer, then the coating process is easier, but heat resistance is insufficient leading to short circuits
Solution Approach 1:
The porous insulating layer is applied in advance to the non-dried electrode layer slurry, establishing the heat-resistant structure before the electrode is fully dried and subjected to high temperature conditions during operation.
Solution Approach 2:
The patent creates a composite structure by coating the porous insulating layer (containing inorganic compounds) on the electrode layer slurry, combining the benefits of easy coating with enhanced heat resistance in the final dried state.
3Reliability
If the porous insulating layer is coated on non-dried electrode layer slurry, then pore blocking is prevented, but the drying process becomes more complex
Solution Approach 1:
The patent merges the drying of the electrode layer slurry and the porous insulating layer into a single simultaneous drying process, eliminating the need for separate drying steps and avoiding increased process complexity while maintaining pore openness.
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 improves the stability and safety of secondary cells by preventing internal short circuits and thermal runaway, while maintaining cell performance through enhanced electrolyte moisture absorption and ion conductance.
Implementation Method 1
improves the stability and safety of secondary cells by preventing internal short circuits and thermal runaway, while maintaining cell performance through enhanced electrolyte moisture absorption and ion conductance
Data Source
AI summary
The present invention provides a manufacturing method of a secondary cell electrode forming a porous insulating layer on at least one surface between a negative electrode and a positive electrode, including coating an electrode layer slurry on the electrode surface, coating the porous insulating layer while in a state in which the electrode layer slurry has not been dried, and simultaneously drying the electrode layer slurry and the porous insulating layer coating slurry so a binder of the porous insulating layer does not block the pores of the electrode layer.