Radiation-Cured Electrode Binders for Battery Manufacturing
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Solution Overview
Problem
The manufacturing of electrodes for lithium ion batteries and electric double layer capacitors is inefficient due to the need for thermal drying, which requires substantial energy and space, and involves costly solvent handling and recovery processes.
Innovation Solution
The use of crosslinked polymeric layers formed via actinic radiation or electron beam curing, incorporating functionalized rubber polymers and particulate materials like carbon and metal oxides, eliminates the need for thermal drying and solvent handling by forming a durable binder that adheres well to current collectors and withstands harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal drying is used to remove solvent from electrode paste, then the binder sets properly, but substantial energy and space are required
Solution Approach 1:
The patent changes the curing mechanism from thermal drying to radiation curing by modifying the binder composition to include photopolymerizable groups. This parameter change allows the binder to cure at room temperature under UV or electron beam radiation, eliminating the need for high-temperature thermal drying ovens and significantly reducing energy consumption while maintaining proper adhesion.
Solution Approach 2:
The patent replaces the thermal field (heat-based drying system) with a radiation field (UV or electron beam). This substitution eliminates the need for large thermal drying ovens, reducing both energy consumption and equipment space requirements while achieving the same binder setting function through photopolymerization.
2Reliability
If thermal drying is used to remove solvent, then the binder sets, but costly solvent handling and recovery processes are required
Solution Approach 1:
The patent changes the binder chemistry to use photopolymerizable groups that cure under radiation. This allows the use of water-based or solvent-free formulations, eliminating the need for expensive solvent recovery systems and reducing manufacturing costs while ensuring proper binder adhesion through radiation-induced crosslinking.
Solution Approach 2:
The patent extracts the solvent removal step from the manufacturing process by using radiation curing. The binder cures in place under UV or electron beam radiation without requiring solvent evaporation, eliminating costly solvent handling and recovery operations while maintaining binder adhesion.
3Reliability
If conventional thermal curing is used, then the binder sets, but manufacturing time is increased due to oven requirements
Solution Approach 1:
The patent replaces the slow thermal drying process with rapid radiation curing. UV or electron beam radiation cures the binder in seconds or minutes compared to hours required for thermal drying, dramatically increasing manufacturing speed and productivity while ensuring reliable binder adhesion through crosslinking.
Solution Approach 2:
The patent skips the lengthy thermal drying step by using radiation curing. The photopolymerizable binder cures rapidly under UV or electron beam radiation, rushing through the curing process in minutes rather than hours, thereby increasing manufacturing throughput while maintaining binder adhesion quality.
4Strength
If polymer binders are designed to retain adhesion and hardness, then electrode integrity is maintained, but they may swell or disintegrate under harsh conditions
Solution Approach 1:
The patent creates a composite binder system combining polymer matrix with photopolymerizable crosslinking agents. The radiation-induced crosslinking forms a three-dimensional network structure that reinforces the polymer, providing both hardness and chemical resistance. This composite approach prevents swelling and disintegration under harsh electrochemical conditions while maintaining adhesion.
Solution Approach 2:
The patent applies radiation curing before the electrode undergoes harsh electrochemical conditions. The photopolymerization process creates a pre-cured, crosslinked network structure that provides beforehand protection against swelling and disintegration, ensuring the binder maintains its mechanical properties and adhesion under subsequent harsh operating conditions.
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 method significantly reduces manufacturing costs and time by eliminating the need for thermal curing ovens, minimizing solvent use, and improving the adhesion and chemical resistance of electrodes, enabling faster production and more efficient energy storage.
Implementation Method 1
The crosslinked matrix can be formed via actinic radiation or electron beam (EB) curing
Implementation Method 2
The crosslinked matrix can be formed via actinic radiation or electron beam (EB) curing
Data Source
AI summary
A process for manufacturing an electrode utilizing electron beam (EB) or actinic radiation to cure electrode binding polymers is provided. A process is also disclosed for mixing specific actinic or EB radiation curable chemical precursors with electrode solid particles, application of the mixture to an electrode current collector, followed by the application of actinic or EB radiation to the current collector for curing the polymer, thereby binding the electrode material to the current collector. Lithium ion batteries, electric double layer capacitors, and components produced therefrom are also provided.