Solid Film Binder for Solvent-Free Battery Electrode Formation
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Solution Overview
Problem
Existing methods for forming lithium-ion battery electrodes require the use of solvents and binders that are costly, time-consuming, and environmentally hazardous, and they limit the flexibility in choosing binder materials.
Innovation Solution
The method involves using one or more substantially solid layers of electrode attachment substance, such as thermoplastic films, to adhere electrochemically active material to a current collector, eliminating the need for solvents and allowing for a roll-to-roll process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based slurry mixes and binders are used to form electrodes, then the electrochemically active material can be adhered to the current collector, but the production process becomes time-consuming and costly due to drying processes and solvent handling
Solution Approach 1:
The patent extracts and eliminates the solvent component from the traditional slurry-based electrode formation process. By using a solid binder material instead of a solvent-based slurry, the drying process and associated time losses are completely removed, while still achieving proper adhesion of electrochemically active material to the current collector
Solution Approach 2:
The patent changes the physical state parameter of the binder material from liquid (solvent-based) to solid form. This parameter change eliminates the need for drying processes and solvent handling, significantly reducing production time while maintaining effective binding functionality
2Reliability
If solvent-based binders are used to adhere electrochemically active material to the current collector, then the material can be properly attached, but environmental hazards and safety concerns arise from solvent handling and disposal
Solution Approach 1:
The patent converts the traditional harmful solvent-based approach into a beneficial solid-state process. By eliminating solvents entirely, environmental hazards and safety concerns are removed, while the solid binder material provides reliable adhesion through its inherent binding properties without requiring harmful chemical substances
Solution Approach 2:
The patent replaces expensive and hazardous solvent-based binder systems with simpler, safer solid binder materials. The solid binders achieve the same adhesion function without the need for costly solvent handling infrastructure, disposal systems, and safety equipment
3Ease of manufacture
If traditional binder materials are used in solvent-based slurry mixes, then the electrochemically active material can be adhered to the current collector, but the choice of binder materials is limited by solubility requirements
Solution Approach 1:
The patent extracts the solubility requirement from the binder selection criteria by eliminating solvents from the process. This allows any solid material with appropriate binding properties to be used as a binder, regardless of its solubility characteristics, dramatically expanding the range of available binder materials
Solution Approach 2:
The patent changes the operational state from liquid slurry requiring solubility to solid-state processing. This parameter change removes the solubility constraint entirely, allowing selection of binder materials based solely on their binding effectiveness, mechanical properties, and compatibility with electrochemically active materials
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 reduces production time and costs by eliminating the need for solvent-based slurry mixes and drying processes, while also providing flexibility in choosing binder materials and potentially improving battery performance.
Implementation Method 1
The layer of electrode attachment substance can comprise a thermoplastic film
Implementation Method 2
adhering can comprise applying heat to the electrode attachment substance and/or the electrochemically active material to adhere the electrochemically active material to the current collector
Implementation Method 3
adhering can comprise applying pressure to the electrode attachment substance and/or the electrochemically active material to adhere the electrochemically active material to the current collector
Data Source
AI summary
In various embodiments, a method of forming an electrode includes providing a current collector, providing a substantially solid layer of electrode attachment substance on a side of the current collector, providing electrochemically active material adjacent the substantially solid layer of the electrode attachment substance, and adhering the electrochemically active material to the side of the current collector via the electrode attachment substance. In some examples, the electrochemically active material is provided in powder form. In some examples, the electrochemically active material is provided between the substantially solid layer of electrode attachment substance and the current collector.