Stepped Electrode Coating Layout for Thick Battery Films
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge of forming a thick coating layer on electrodes for high-capacity secondary batteries is complicated by the difficulty in evenly manufacturing electrodes with multiple layers, leading to unevenness and overlapping rising portions, which affects electrode plate resistance.
Innovation Solution
The electrode is designed with a coating layer comprising two or more layers that do not overlap, featuring a first layer coated in one direction and a second layer forming a step with the first layer, ensuring even distribution and reduced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the coating layer is formed as a single layer to achieve high capacity, then the battery capacity increases, but the coating becomes difficult and the electrode manufacturing becomes uneven
Solution Approach 1:
The coating layer is divided into multiple sub-layers (first coating layer, second coating layer, third coating layer) instead of forming a single thick layer. Each sub-layer is applied sequentially with different orientations, making the coating process more controllable and uniform while achieving the required total thickness for high capacity
Solution Approach 2:
The patent introduces multi-directional coating by applying coating layers in different orientations (first direction, second direction perpendicular to first, third direction perpendicular to second). This dimensional approach prevents overlapping of rising portions and ensures uniform distribution of active material throughout the thick coating
2Length of stationary object
If the coating layer thickness is increased for high capacity, then the battery capacity increases, but the coating process becomes more difficult and manufacturing unevenness occurs
Solution Approach 1:
The thick coating layer is segmented into multiple thinner sub-layers applied in sequence. This segmentation reduces the difficulty of each individual coating step while achieving the required total thickness, making the manufacturing process more manageable and less prone to defects
Solution Approach 2:
Each subsequent coating layer is applied after the previous layer has been formed, with preliminary preparation including drying and orientation adjustment. This step-by-step preliminary action ensures each layer is properly prepared before the next is applied, reducing manufacturing difficulties
3Length of stationary object
If multiple coating layers are applied to achieve thick film, then the coating thickness increases, but overlapping of rising portions causes unevenness
Solution Approach 1:
Each subsequent coating layer is applied in a direction perpendicular to the previous layer (first direction → second direction perpendicular to first → third direction perpendicular to second). This dimensional change ensures that rising portions of different layers do not overlap, maintaining coating uniformity and compositional stability
Solution Approach 2:
The patent introduces asymmetric coating orientations where each layer is applied at a different angle relative to the substrate. This asymmetric approach prevents the formation of overlapping rising portions that would occur with symmetric, parallel coating directions
4Quantity of substance
If the coating layer is made thicker for high capacity, then the battery capacity increases, but the electrode plate resistance increases
Solution Approach 1:
The thick coating is divided into multiple sub-layers with conductive material added at each interface. This segmentation reduces the overall resistance by creating multiple conductive pathways through the thick coating, allowing high capacity to be achieved without excessive resistance
Solution Approach 2:
Conductive material is introduced as an intermediary substance at the interfaces between coating layers. This intermediary reduces the electrical resistance between layers, enabling thick coatings to maintain low overall resistance while providing high capacity
Data Source
AI summary
An electrode and a secondary battery are disclosed. An electrode includes a substrate, and a coating layer including a first coating layer coated on a side of the substrate in a first direction, and a second coating layer coated on another side of the substrate in a second direction, and the coating layer includes a first layer and a second layer located on the first layer and defining a step with the first layer.