Solvent-Free Electrode Manufacturing via Granular Powder Lamination
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Solution Overview
Problem
The manufacturing process of lithium secondary batteries is hindered by the need for expensive and time-consuming drying devices to control solvent evaporation rates, leading to defects like pinholes and cracks in the electrode active layer, and poor manufacturing processability.
Innovation Solution
A method of manufacturing electrodes by preparing a mixture bulk without solvents, milling it into granular powder, scattering and laminating it on a metal current collector, and rolling it to form a layer, eliminating the need for a drying process and improving processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a drying process is used to remove solvent from electrode mixture, then solvent evaporation can be controlled, but manufacturing cost increases and defects like pinholes and cracks occur
Solution Approach 1:
The invention extracts and removes the solvent component from the electrode mixture formulation, creating a solvent-free granular powder composition that can be directly applied to the current collector without requiring a drying process, thereby eliminating the technical contradiction between electrode quality and manufacturing processability
Solution Approach 2:
The invention changes the physical and chemical parameters of the electrode mixture by eliminating the solvent component and adjusting the particle size distribution of the granular powder to 30-180 micrometers, enabling the mixture to be applied and laminated without solvent evaporation, thus resolving the contradiction between controlled drying and manufacturing ease
2Manufacturing precision
If a drying device is used to control solvent evaporation rate, then uniform drying can be achieved, but manufacturing cost and operation time increase significantly
Solution Approach 1:
The invention removes the solvent component that requires drying, creating a solvent-free granular powder that can be directly laminated onto the current collector, thereby eliminating the need for expensive and time-consuming drying devices while maintaining uniform electrode structure
Solution Approach 2:
The invention performs preliminary granulation and size classification of the electrode materials before application, creating uniformly sized granular powder (30-180 micrometers) that ensures even distribution and lamination without requiring subsequent drying operations, thus improving both precision and productivity
3Ease of manufacture
If solvent is used in electrode mixture to provide fluidity, then coating can be performed, but drying defects like pinholes and cracks are induced
Solution Approach 1:
The invention extracts and eliminates the solvent component from the electrode mixture, replacing it with a solvent-free granular powder system that provides coating processability through particle flow and lamination characteristics rather than liquid fluidity, thereby preventing drying defects like pinholes and cracks
Solution Approach 2:
The invention uses a simple granular powder formulation without solvent that can be directly applied and laminated, replacing the complex solvent-based slurry system, thereby eliminating the harmful drying defects while maintaining ease of manufacture through straightforward processing
Data Source
AI summary
The present invention provides a method for manufacturing an electrode, the method comprising the steps of: preparing a lump of mixture bulk; milling the mixture bulk to prepare granular powder having an average particle diameter of 30 micrometers to 180 micrometers; sprinkling the granular powder on the surface of a metal current collector; and rolling the granular powder on the metal current collector to laminate the granular powder on the metal current collector.