Shear-Thinning Liquid Composition for Scatter-Free Discharge Coating
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Solution Overview
Problem
The scattering of liquid compositions during discharge leads to impaired image quality and safety hazards in the production of electrochemical elements like lithium ion secondary batteries, due to mist, liquid separation, and rebounding phenomena.
Innovation Solution
A liquid composition with specific shear viscosity characteristics (ηA ≥ 1000 mPa·s at 10−1 s−1 and ηB ≤ 100 mPa·s at 105 s−1) is used, along with a liquid discharger that includes a discharge device with multiple ports, to control the discharge and landing of the liquid on a base, reducing scattering and ensuring uniform film formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the liquid composition is discharged using conventional methods, then the discharge process is simple, but liquid scattering (mist, separation, rebounding) occurs leading to safety hazards and impaired image quality
Solution Approach 1:
The patent applies parameter changes by precisely controlling the viscosity of the liquid composition at different shear rates. Specifically, the liquid composition is designed to have a viscosity of 100-10000 mPa·s at a shear rate of 10^-1 s^-1 and 1-100 mPa·s at a shear rate of 10^5 s^-1. This parameter optimization prevents liquid scattering during discharge while maintaining dischargeability, thereby improving safety and image quality without requiring complex additional discharge control devices.
2Manufacturing precision
If the viscosity of the liquid composition is increased to prevent scattering, then coating uniformity improves, but the liquid becomes difficult to discharge
Solution Approach 1:
The patent applies dynamics by designing the liquid composition with non-Newtonian fluid characteristics, specifically exhibiting different viscosity behaviors at different shear rates. The composition maintains high viscosity (100-10000 mPa·s at 10^-1 s^-1) during static or low-speed conditions to ensure coating uniformity, while automatically reducing to low viscosity (1-100 mPa·s at 10^5 s^-1) during high-speed discharge. This dynamic viscosity adjustment resolves the contradiction between coating precision and dischargeability.
Solution Approach 2:
The patent utilizes parameter changes by optimizing the viscosity characteristics of the liquid composition across different shear rate conditions. The specific parameter range (100-10000 mPa·s at low shear rate, 1-100 mPa·s at high shear rate) enables the liquid to maintain uniformity during coating while remaining easily dischargeable, eliminating the need to choose between the two opposing requirements.
3Loss of substance
If conventional liquid compositions are used, then material loss is reduced compared to contact methods, but liquid scattering causes contamination and safety hazards
Solution Approach 1:
The patent applies parameter changes by optimizing the viscosity characteristics of the liquid composition to prevent scattering while maintaining non-contact discharge efficiency. The controlled viscosity range (100-10000 mPa·s at 10^-1 s^-1, 1-100 mPa·s at 10^5 s^-1) ensures that the liquid forms stable droplets or streams during discharge, preventing mist formation, liquid separation, and rebounding. This resolves the contradiction by maintaining material efficiency while eliminating harmful scattering effects through parameter optimization rather than additional containment measures.
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 solution effectively prevents mist and rebounding, maintaining image quality and safety by ensuring uniform coating and reducing contamination risks in the manufacturing process.
Implementation Method 1
ηA is a viscosity of the liquid composition at a shear rate of 10−1 s−1 and the ηA is equal to or greater than 1000 mPa·s. ηB is a viscosity of the liquid composition at a shear rate of 105 s−1 and the ηB is equal to or smaller than 100 mPa·s
Data Source
AI summary
A liquid composition includes an active material and a dispersion medium. ηA is a viscosity of the liquid composition at a shear rate of 10−1 s−1 and the ηA is equal to or greater than 1000 mPa·s. ηB is a viscosity of the liquid composition at a shear rate of 105 s−1and the ηB is equal to or smaller than 100 mPa·s.