Solventless Multilayer Electrode Compression Without Drying Steps
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Solution Overview
Problem
Conventional electrochemical cell manufacturing processes rely on solvents that are costly and environmentally harmful, requiring extensive drying steps and increasing production costs and environmental hazards.
Innovation Solution
The development of solventless multilayered electrodes, where dry electrode mixtures are compressed into standalone films using patterned rollers to form interpenetrating boundary structures, eliminating the need for solvents and reducing manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvents are used in conventional electrode manufacturing processes, then the electrode materials can be processed and formed into electrodes, but the manufacturing cost increases and environmental harm is caused
Solution Approach 1:
The patent removes solvents entirely from the electrode manufacturing process. Dry electrode mixtures are compressed directly between patterned rollers to form electrodes with interpenetrating boundary structures, eliminating the need for solvent-based slurry processing and subsequent drying steps.
Solution Approach 2:
The patent changes the physical state of the electrode material from a solvent-based slurry to a dry mixture. By compressing dry electrode mixtures under pressure, the material transitions from loose particles to a densely packed electrode structure with improved adhesion and electrochemical performance.
2Ease of manufacture
If solvents are used in electrode manufacturing, then the electrode components can be combined, but extensive drying steps are required which increase manufacturing time
Solution Approach 1:
The patent extracts and eliminates the drying step from the manufacturing process by removing solvents entirely. The dry compression method allows electrode components to be combined and formed in a single step without requiring subsequent drying or curing operations.
Solution Approach 2:
The patent performs the binding action during the compression step itself rather than requiring a separate drying step. The patterned rollers create interpenetrating boundary structures that provide mechanical interlocking and adhesion between layers during compression, eliminating the need for post-compression drying.
3Ease of manufacture
If solvents are used in the manufacturing process, then the electrode mixture can be formed, but hazardous waste is generated requiring additional environmental controls
Solution Approach 1:
The patent converts the potential harm of solvent use into a benefit by completely eliminating solvent-based processes. The dry compression method transforms what would be hazardous waste generation into an environmentally benign process where no solvents are introduced, and therefore no solvent waste is produced.
4Ease of manufacture
If conventional manufacturing methods are used, then the process is well-established, but the manufacturing cost is high due to solvent expenses
Solution Approach 1:
The patent replaces expensive solvent-based materials with inexpensive dry electrode mixtures. The patterned rollers create structures that provide adhesion and integrity without requiring costly solvent binders, reducing material costs while maintaining electrode performance.
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 the use of expensive and hazardous solvents, allows for multiple active materials in different layers, improves surface adhesion, and decreases manufacturing time by eliminating drying steps, while enhancing electrochemical properties and control over layer features.
Implementation Method 1
compressing a first dry electrode mixture between a first pair of rollers to form a first standalone electrode film
Implementation Method 2
increasing a surface roughness of a first surface of the first standalone electrode film using the first patterned roller
Implementation Method 3
a first active material layer layered onto the current collector substrate, the first active material layer comprising a first stand-alone electrode film including a plurality of first active material particles adhered together by a first binder mixture
Data Source
AI summary
A method for manufacturing a solventless multilayered electrode may include mixing electrode particles with binders to form dry electrode mixtures, compressing the dry electrode mixtures to form electrode films, stacking the electrode films, and compressing the stacked electrode films. Suitable electrode films may include active material particles, conductive particles, electrochemically inactive ceramic particles, and/or the like. In some examples, compressing the stacked electrode films may include compressing the electrode films between pairs of rollers having patterns disposed on one or more exterior surfaces, thereby increasing surface roughness of the electrode films. A system for manufacturing solventless multilayered electrodes may comprise a first plurality of rollers configured to compress dry electrode mixes into electrode films, and a second plurality of rollers configured to compress a stack of electrode films into a single electrode stack.