Textured Dry Electrode Interface for Adhesive-Free Lamination

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Solution Overview

Problem

Conventional dry electrodes for rechargeable batteries suffer from reduced battery capacity due to decreased active material content, increased manufacturing costs, and inefficiencies in thickness, weight, and volume, primarily because of the use of adhesive layers that reduce the amount of active material.

Innovation Solution

A dry electrode design featuring a current collector with protrusions and depressions, directly laminating a free-standing film containing an active material, conductive material, and fiberized binder, eliminating the need for adhesive layers by enhancing surface contact area through surface treatments like etching and electrolytic plating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an adhesive layer is coated on the current collector to adhere the free-standing film, then the free-standing film is securely attached to the current collector, but the battery capacity is reduced due to decreased active material content and manufacturing costs increase

Engineering Contradiction:

Improveadhesion between free-standing film and current collectorVSAvoidactive material content

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent removes the adhesive layer from the battery structure entirely. Instead of using an adhesive layer to bond the free-standing film to the current collector, the invention relies on the mechanical interlocking provided by the protrusions and depressions on the current collector surface, thereby eliminating the harmful adhesive layer and maximizing active material content

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The current collector surface is designed with protrusions and depressions that create a three-dimensional curved surface topology. This irregular surface geometry provides increased surface area and mechanical interlocking features that enable secure adhesion of the free-standing film without requiring a separate adhesive layer

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Reliability

If an adhesive layer is coated on the current collector, then the free-standing film is securely attached, but the dry electrode thickness, weight, and volume increase

Engineering Contradiction:

Improveadhesion between free-standing film and current collectorVSAvoiddry electrode thickness

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The adhesive layer is completely removed from the battery structure. The free-standing film is attached directly to the current collector through mechanical interlocking with the protrusions and depressions, eliminating the additional thickness contributed by the adhesive layer

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The three-dimensional protrusion and depression structure on the current collector provides secure mechanical interlocking within a minimal thickness profile, achieving strong adhesion without adding significant thickness to the overall electrode structure

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Reliability

If an adhesive layer is coated on the current collector, then the free-standing film is securely attached, but manufacturing costs increase

Engineering Contradiction:

Improveadhesion between free-standing film and current collectorVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The adhesive layer is eliminated from the manufacturing process. The current collector is formed with integrated protrusions and depressions that provide self-adhesion functionality, removing the need for separate adhesive materials and the coating processes required to apply them

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The current collector serves multiple functions: it provides electrical conductivity, structural support, and adhesion functionality through its protrusion and depression structure. This multi-functionality eliminates the need for separate adhesive layers and reduces manufacturing complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 design maximizes battery capacity, reduces manufacturing costs, and increases the thickness, weight, and volume of the dry electrode by eliminating the need for adhesive layers and optimizing surface contact.

Implementation Method 1

The metal layer may be formed by providing a seed on the surface of the primer layer and then electrolytically plating the seed

Methodology Applied

Scientific EffectElectrolytic plating: Electroplating

Implementation Method 2

The surface of the current collector having protrusions and depressions may be etched

Methodology Applied

Scientific EffectEtching: Ablation

Implementation Method 3

a free-standing film including an active material, a conductive material, and a fiberized binder and laminated directly onto the surface of the current collector

Methodology Applied

Scientific EffectLamination: Lamination

Data Source

PatentUS20250309276A1Dry electrode and dry electrode manufacturing method

Publication Date: 2025.10.02 SAMSUNG SDI CO LTD

AI summary

A dry electrode includes a current collector including a surface having protrusions and depressions and a free-standing film including an active material, a conductive material, and a fiberized binder. The free-standing film is laminated directly onto the surface of the current collector having protrusions and depressions.