Thick Battery Electrode Plate via Viscoelastic Binder Network
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Solution Overview
Problem
Current methods for preparing thick battery electrode plates (>1 mm) face challenges such as low active material loading, environmental pollution from volatile organic solvents, and limited cycle life, making it difficult to achieve high capacity, high power, and long cycle life in electrochemical energy storage devices like lithium-ion batteries and lead-acid batteries.
Innovation Solution
A method involving mixing electrode active materials with a conductive polymer, followed by milling and extrusion to create a uniform active membrane, which is then cut and pressed with a current collector under high temperature and pressure to form a thick electrode plate with a flexible organic network structure, enhancing mechanical strength and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional coating methods are used to prepare electrode plates, then the process is simple and equipment cost is low, but the active material loading is low and the thickness is limited to less than 300 μm
Solution Approach 1:
The patent changes the physical state parameters of the binder from solid rubber particles to liquid viscoelastic body through temperature control and plasticizer addition, enabling the binder to flow and penetrate into the active material pores, thereby increasing active material loading capacity
Solution Approach 2:
The patent creates a composite structure where the viscoelastic binder forms a flexible organic network that penetrates and bonds with the active material particles, forming an integrated composite electrode plate with enhanced loading capacity and structural integrity
2Manufacturing precision
If volatile organic solvents are used for dispersion homogenization, then the mixing process is effective, but environmental pollution occurs
Solution Approach 1:
The patent replaces harmful volatile organic solvents with water as the dispersion medium, eliminating environmental pollution while maintaining effective homogenization through the viscoelastic properties of the rubber binder that facilitates particle distribution without requiring organic solvents
Solution Approach 2:
The patent introduces a plasticizer as an intermediary substance that modifies the binder's viscoelastic properties, enabling effective dispersion and homogenization of active materials without the need for volatile organic solvents, thus achieving both mixing effectiveness and environmental friendliness
3Power
If nano-materials with high specific surface area are used, then the capacity and rate capability are improved, but the tap density is low and secondary granulation is needed
Solution Approach 1:
The patent uses the viscoelastic binder to form a flexible organic network that acts as a binding matrix around nano-material particles, maintaining their high specific surface area for good rate capability while providing structural support that enables direct plate formation without secondary granulation
Solution Approach 2:
The patent applies the viscoelastic binder locally at the interfaces between nano-material particles, creating strong local bonds that aggregate particles into a cohesive structure with improved tap density while preserving the high surface area characteristics of individual nano-particles for maintaining rate capability
4Quantity of substance
If the electrode plate thickness is increased to improve energy density, then the active material proportion increases, but the consistency control becomes difficult
Solution Approach 1:
The patent creates a continuous flexible organic network throughout the electrode plate using the viscoelastic binder, which maintains structural continuity and uniformity even at thicknesses greater than 1.0 mm, enabling consistent performance and easy quality control across the entire plate
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
The resulting electrode plates exhibit high consistency, viscoelasticity, and improved ion transmission, leading to increased cycle life, high energy density, and reduced internal resistance, making them suitable for various battery types including lead-acid, lithium-ion, and supercapacitors.
Implementation Method 1
The resulting electrode plates exhibit high consistency, viscoelasticity, and improved ion transmission
Implementation Method 2
improved ion transmission, leading to increased cycle life, high energy density, and reduced internal resistance
Data Source
AI summary
A new type of battery electrode plate preparation method is described. The method can include the following steps: a) a mixing process; b) a milling and polishing process; c) an extrusion shearing and extending process; d) cutting to obtain an electrode membrane; and e) pressing at a high temperature and a high pressure to obtain a battery electrode plate. The method can adopt the active material of different electrochemical batteries as the main body to prepare a thick type battery electrode plate with a high conductivity, a high capacity and a high active material loading, which has a viscoelastic body. The electrode plate can have a flexible organic network structure and an excellent mechanical strength, and can still exist in a variety of electrolytes after hundreds of times or even thousands of times of deep charge and discharge cycles. The thick electrode plate prepared by using the method can be applied to a variety of batteries such as lead-acid battery positive and negative electrode plates, a lead carbon battery electrode plate, a lithium ion battery electrode plate, a supercapacitor electrode plate, a Ni-MH battery electrode plate, and others.