Mixing and Coating Techniques for EV Battery Electrode Materials

Electrode material for batteries with improved cycle life and reduced expansion/contraction during charging/discharging. The electrode material has a core-shell structure made by spray drying. The core contains functional components, binder, and conductive agent. A shell layer with different binder and conductive content is sprayed onto the core. This provides a lower inner core conductivity and binder content compared to the shell. This prevents excessive expansion/contraction during cycling, preventing collapse and improving cycle life.

Source

A method to manufacture electrodes for all-solid-state batteries that improves performance and enables using solid electrolytes. The method involves making larger primary electrode granules with a binder, then mixing them with solid electrolyte and compressing to form smaller secondary granules. These secondary granules have a solid electrolyte coating that densely adheres to the electrode material. This provides better solid-state electrolyte coverage on the electrode compared to using the solid electrolyte directly. The larger primary granules allow better mixing and compression during mechanofusion to coat the secondary granules.

Source

A set of liquid compositions for forming electrode layers in lithium-ion batteries that improves flexibility and ease of design compared to using a single liquid composition. The set includes two compositions, one with a first electrode material dissolved in a first liquid, and the other with a second electrode material dissolved in a different second liquid. This allows optimizing solubility/dispersibility of each electrode component in its respective liquid. Applying the set sequentially or simultaneously onto the electrode substrate enables forming electrode layers with better adhesion, peel strength, and capacity compared to using a single composition.

Source

Manufacturing method for electrodes in rechargeable lithium batteries that improves adhesion, cycle life, and high-rate charging performance. The method involves applying an electric field during drying to control binder migration and distribution. This prevents binder buildup on the electrode surface that can hinder ion transfer and degrade electrochemical properties. The electric field is applied in a direction perpendicular to the drying direction to counteract capillary forces and prevent binder migration.

Source

Method for manufacturing electrodes for batteries that reduces electrode peeling during drying and improves yield. The method involves a kneading step using a heating stirring process at 150-200°C followed by a defoaming stirring process. The heating stirring removes moisture from the raw materials to prevent peeling during drying.

Source

Method for making dry electrodes for batteries that improves conductivity, avoids solvent side reactions, and enhances performance compared to wet electrodes. The dry electrode manufacturing process involves coating the active material, conductive agent, and binder mixture directly onto the current collector without using a solvent. The coated mixture is preliminarily hot-pressed, then a glue layer is plated on the surface. Baking and drying removes moisture from the glue. This eliminates the need for a solvent surrounding the particles, improving contact and conductivity. It also prevents solvent reactions with the electrolyte.

Source

Electrode for an electrochemical device with improved adhesion strength between a free-standing dry electrode film and a current collector. The method involves forming an attachment enhancing layer on the current collector by coating a slurry of binder and conductive material, then stacking the dry electrode film on it and applying heat/pressure to permeate the binder into the electrode film surface. This enhances adhesion compared to direct film-current collector contact. The attachment layer prevents film delamination during cell assembly/operation.

Source

Electrode design and manufacturing method for lithium secondary batteries that prevents capacity imbalance and improves safety by preventing sliding at the electrode ends. The electrode has a single layer with an electrode mixture containing active material and an auxiliary coating at the end. The auxiliary coating layer improves adhesion, prevents thickness variation, and acts as a dam to prevent sliding at the end. This prevents capacity ratio inversion and lithium plating issues. The auxiliary coating is prepared by simultaneously applying an electrode slurry and auxiliary coating composition onto the current collector.

Source

Active material for dry electrode formation in lithium-ion batteries that has conductive filler particles already embedded in the active material particles. This improves electrode performance by providing better electrical conductivity compared to adding external conductive additives during electrode formation. The active material powder is mixed with conductive filler and then dried to form particles with conductive filler already attached. This pre-embedded active material is then used to coat the electrode current collector in the dry electrode formation process.

Source

Method for manufacturing battery electrodes with improved flatness and reduced thickness variation of the active material layer. The key is coating the electrode slurry at a speed that exceeds the yield point of the slurry. The slurry has specific flow properties with a region where shear stress is constant and a region where shear stress increases with speed but at decreasing rate. Coating at speeds exceeding the yield point prevents sagging and improves layer uniformity.

Source

Negative electrode, manufacturing method, and secondary battery with improved lifespan and capacity retention for silicon-based negative electrodes in lithium-ion batteries. The method involves applying a thin layer of styrene butadiene rubber onto the current collector before adding the silicon active material and binder. This primer layer reduces expansion and contraction of the silicon during charging/discharging and improves flexibility compared to using the binder alone.

Source

A method for producing lithium ion battery electrodes that suppress cracking of the electrode active material during formation of the electrode and improve battery storage characteristics. The method involves pressing composite particles containing electrode active material and binder onto a substrate to form a compressed layer. This is followed by further pressing the compressed layer to form the electrode mixture layer. The key is to set the pressing temperature during both steps to be equal to or higher than the softening point of the water-soluble polymer in the binder. This prevents active material distortion and cracking. By dividing the pressing into two stages, the density can be increased without excessive stress. Using a binder with a softening point below the pressing temp also helps.

Source

Method for manufacturing high-performance lithium secondary battery electrodes with improved adhesion and productivity. The method involves using a dehydration process with a porous substrate to remove a significant amount of solvent from the electrode slurry before applying it to the current collector. This allows faster drying rates compared to traditional methods. Additionally, a coating solution containing a binder is applied to the current collector prior to laminating the electrode layer. This improves adhesion between the active material and current collector. The dehydrated electrode layer is then pressed onto the binder-coated current collector to physically bind them. After separating the porous substrate, the electrode is further dried.

Source

Preparation method of lithium ion battery with high cycle performance by using a mixed positive electrode. The method involves mixing high voltage positive electrode active particles like nickel-cobalt-manganese ternary cathode material with conductive carbon black, spreading it on a battery current collector, and forming an electrode plate using binder spraying. This provides high specific capacity from the high voltage material. A coating of low voltage positive electrode active particles like lithium iron phosphate is then applied using spray drying or coating techniques on the electrode. This improves cycle life and safety by reducing voltage stress. The mixed positive electrode with optimized composition and structure from the preparation method enhances the energy density, cycling stability, and safety of the lithium ion battery.

Source

Preparation method for thick lithium-ion battery electrodes that allows high energy density without capacity degradation. The method involves mixing the electrode active material, conductive agent, binder, salt, and solvent to form a slurry. Then heating the slurry to 110-180°C to compound it with the current collector. This allows thick electrodes with high active material content and reduced tortuosity for improved ion and electron transport compared to conventional methods. The slurry is coated onto the current collector or pressed onto it.

Source

Stabilizing slurry and electrophoretic deposition (EPD) bath suspensions for energy storage electrodes and separators to prevent particle agglomeration and settlement. The stabilization involves using specific deflocculating agents that reduce aggregation of nanoparticles and microparticles. These agents are selected from materials like phosphates and electron rich compounds with small effective radius. They are added to the carrier liquid before introducing the solid particles to create stable suspensions for electrode preparation and EPD deposition. The stabilized suspensions enable uniform electrode deposition with controlled particle size distribution.

Source

A method to manufacture electrodes for all-solid-state batteries with high active material loading and uniform thin film thickness. The method involves using two binders: a first binder dispersed in a solvent to form an adhesive solution, and a second binder added later. The active material and solid electrolyte are mixed into a first slurry, then a second slurry is made by adding more binder solution. The second slurry is kneaded to fibrillate the second binder into a clay-like state. This fibrillated second binder provides mechanical properties to the electrode. Rolling the clay-like material forms the electrode. The fibrillated second binder allows uniform distribution and packing of the active material.

Source

A secondary battery electrode coated with nanoscale metal particles instead of a separate conductive material or binder. The electrode active material is coated with nanoscale metal particles like tin, silver, copper, antimony, lead, or solder alloys. The metal particles bond the active material together during sintering. This eliminates the need for a separate conductive material or binder for electrical contact and adhesion. The metal coating allows dense packing of the active material without volume expansion during charging/discharging. It also improves electrical conductivity compared to using a binder. The coated electrode can be made by immersing the active material in a dispersion of metal particles, drying, and pressing.

Source

Method for preparing a negative electrode slurry for lithium-ion batteries with improved conductivity and reduced volume expansion during charging/discharging for silicon-based anodes. The slurry is prepared in two steps: (1) mixing a silicon-based negative electrode active material, conductive agent, and binder to form a first slurry; (2) adding carbon-based negative electrode active material and thickener to the first slurry and mixing. This allows a higher concentration of conductive agent around the silicon particles to improve conductivity. The thickener also helps prevent separation between the silicon and carbon particles during volume expansion.

Source

A surface treatment system and device for ternary positive electrode materials in lithium-ion batteries that improves coating uniformity and efficiency. The system involves separate steps of primary sintering, coating, secondary sintering, and smashing to treat the electrode material. This allows better mixing of the electrode and coating materials compared to conventional methods. The primary sintering step is done first to densify the electrode material. Then coating is applied. After coating, secondary sintering is done to further densify the electrode material and bond the coating. Finally, smashing is done to break up any agglomerates formed during sintering. This sequential treatment sequence helps ensure homogeneous mixing and dispersion of the coating material with the electrode material.

Source

A method for manufacturing electrodes for energy storage devices like batteries and ultracapacitors that provides uniform dispersion of slurries on current collectors without voids. The method involves heating a solvent mixture, adding active materials and dispersant to form a slurry, coating the current collector with the slurry, and calendering to compact the coating into the electrode. The heating step improves dispersion of the active materials and prevents agglomeration.

Source

Preparation method for ultrathin single-particle layer electrodes for lithium-ion batteries without foil leakage. The method involves using a low-solid content slurry (1-10% solid content) with specific viscosity (2500-8000 mPa·s) and density (0.5-1 g/cm3) to coat the electrode on the current collector. This allows thin electrode formation in larger coating gaps compared to conventional slurries. The low-solid content prevents foil leakage and forms a smooth, single-particle layer electrode.

Source

A method to manufacture a solvent-free electrode for electric energy storage devices like batteries and capacitors that improves electrical performance by increasing density without using solvents. The method involves kneading a mixture of electrode active material, binder, and conductive material in a kneader instead of stirring with a solvent. The kneading promotes bonding between components without solvent and allows uniform mixing. This eliminates the need for drying and simplifies manufacturing compared to solvent-based methods.

Source

Preparation method for dry electrode sheets for lithium-ion batteries that avoids solvent volatilization during electrode production. The method involves mixing the electrode slurry without solvent using non-destructive stirring techniques like planetary, 3D, or twin-helical stirring. This allows forming the electrode film without solvent addition and reduces environmental pollution and manufacturing costs compared to wet methods.

Source

Coating method for making thinner, higher capacity battery electrodes by coating the positive and negative materials on opposite sides of a composite current collector. This allows using thinner electrodes with more winding layers in the same battery case volume, increasing capacity. The key is coating the positive material on one side first, drying it, then coating the negative material on the other side and drying. This prevents cracking and curling of the previously coated layer.

Source

Coating apparatus and method for forming uniform and stable electrode layers in secondary batteries. The method involves using a coating device to apply a mixture of battery electrode materials onto an electrode substrate. The coated electrode is then pressed to compact the mixture. This consolidation step helps achieve a uniform and stable electrode layer thickness compared to slurry coating methods. The pressed electrode can then be dried and further processed for the battery assembly.

Source

A method to improve the performance of lithium-ion battery positive electrodes by alternately coating layers of ternary positive electrode slurry and carbon conductive agent slurry on the current collector. This improves liquid retention and electrolyte passage compared to coating only the positive electrode slurry. It involves coating, drying, and rolling each layer. The carbon conductive layer between positive electrode layers helps trap electrolyte and prevent dry spots.

Source

Thick electrode for lithium-ion batteries with improved rate performance and cycle life compared to conventional thick electrodes. The thick electrode is prepared by grooving the semi-solid coating before drying to form a structured surface with regularly spaced grooves. This prevents damage to the active material during coating and provides a high-porosity electrode with enhanced liquid phase transport for improved rate capability and cycle stability. The grooving step can be performed continuously or indirectly during coating.

Source

A liquid composition for electrode production that improves the productivity of electrodes and electrochemical devices like lithium-ion batteries. The composition contains an active material dispersed in a low dielectric constant solvent with a dielectric constant of 30 or less at 25°C. This reduces the viscosity of the liquid composition, allowing easier ejection by inkjet printers and higher active material loading compared to conventional dispersion media like NMP. The low viscosity also facilitates spreading and coating of the electrode materials.

Source

A method to manufacture composite electrodes for all-solid-state batteries by synthesizing the solid electrolyte coating on the electrode material during the slurry preparation step. The method involves mixing the solid electrolyte precursor and a polar solvent to prepare the precursor solution, stirring it, adding the active material to make the electrode slurry, and heat treating it to form the coating layer with the solid electrolyte. This allows simultaneous synthesis and coating of the solid electrolyte on the electrode material compared to separate steps.

Source

Preparing electrodes with high areal density, improved adhesion, and reduced cracking for electrochemical devices like batteries and supercapacitors using a spray drying method. The method involves preparing a slurry with controlled viscosity and spraying it onto the electrode substrate. The droplets rapidly dry before the binder can shrink into the porous material. This prevents cracking and material drop compared to traditional coating methods where the binder shrinks during drying. The result is electrodes with better surface density and adhesion.

Source

Electrode design and manufacturing method for secondary batteries with increased capacity and reduced resistance. The method involves coating an electrode slurry on the current collector, then forming a separate conductive material layer on the slurry surface. This creates a sandwiched structure with an inner electrode active layer and outer conductive layer. The separate conductive layer improves capacity and reduces resistance compared to directly adding conductive material to the slurry.

Source

Electrode for lithium-ion batteries with improved binding strength and energy density compared to conventional electrodes. The electrode has a dendritic polymer chemically bonded to the surface of the electrode active material, and the dendritic polymer is also chemically bonded to the binder. This configuration increases binding strength without increasing binder amount. The density of the electrode mixture after impregnation with electrolyte is at least 95% of the dry density. The electrode manufacturing method involves forming the electrode mixture on a current collector, pressing at a first temperature, and vacuum drying at a second temperature to achieve the desired density.

Source

A lithium secondary battery with a high-speed charging and discharging anode that doesn't require a separate synthesis process and is cost-effective. The anode is made by coating a slurry of silicon nanoparticles, binder, and conductive material onto a current collector, then surface treating it under inert gas. The treatment generates radicals that react with the anode to improve charge/discharge performance. The anode can have high energy density due to the silicon nanoparticles, but the graphite conductive material provides stability.

Source

Reducing resistance and improving performance of lithium-ion battery electrodes by selectively removing binder from the surface during manufacture. The process involves coating an electrode slurry onto a current collector, drying to form the active material layer, and then surface treating to remove binder from the layer surface. This prevents binder buildup on the active material surface which can increase resistance and degrade battery performance. By limiting binder content in the surface layer to 0-1% of the total, adhesion is maintained while avoiding surface binder issues.

Source

Solventless fabrication of lithium battery electrodes using a roller process instead of the conventional slurry coating method. The solventless electrode preparation involves mixing dry electrode materials like active particles, conductive carbon, and binder above the binder's melting point. This provides better binding as the expanded binder coats more surface area. The dough is then rolled to thin electrode sheets. The roller design addresses the unique properties of dry electrodes. The roller's motion and temperature control reduce thickness while spreading the dough. This enables high capacity dry electrodes above 5 mAh/cm2 with good cycling performance.

Source

A method for fabricating electrodes for energy storage devices that improves performance and reduces manufacturing costs. The method involves mixing the energy storage materials and solvent at high temperature, adding dispersant, and then coating the current collector with the slurry. Calendering the slurry provides a smooth, uniform electrode surface. This eliminates voids, roughness, and inconsistencies compared to traditional slurry application.

Source

A method to improve the adhesion between the electrode active material and the current collector in secondary batteries. The method involves mixing the active material, conductive agent, binder, and first solvent, then adding a second solvent with higher density than the first solvent. This second solvent helps strengthen the adhesion by distributing from the active material to the current collector side. After coating the electrode, drying is delayed for a period to allow the second solvent to migrate and improve adhesion.

Source

Preparing electrode slurry for lithium batteries that reduces wire dragging during coating and improves electrode quality. The slurry is prepared in two steps. First, a high viscosity slurry is made with just some binder, active material and conductive material. Then, a lower viscosity slurry is made by adding the remaining binder. This two-step process allows adjusting the slurry viscosity to minimize wire drag during coating.

Source

Preparing electrode tabs for lithium-ion batteries with improved electrical performance by ensuring uniform coating of slurry on the current collector. The method involves: 1) dispersing electrode active material powder in solvent to form a slurry, 2) adding a polymer binder to the slurry, 3) stirring the slurry, 4) casting the slurry onto the current collector, 5) drying the slurry in a controlled manner to prevent cracking or deformation, and 6) cutting the dried tab to size. This controlled drying step allows uniform drying of the slurry without skin formation, ensuring even distribution of binder and active material on the current collector.

Source

A dry method for preparing lithium battery electrodes that improves battery performance and reduces manufacturing costs compared to traditional wet slurry methods. The dry method involves mixing specific proportions of dry powdered components like active materials, conductive agents, binders, and solvents to make the electrode. This avoids the need for extensive wet processing steps like ball milling and solvent addition. The dry mixture is compacted into the electrode shape using hot rolling. The dry preparation reduces defects, improves consistency, and enables higher active material loading compared to wet methods.

Source

A manufacturing method for solid-state batteries with reduced binder content that allows faster coating, higher packing density, and improved performance. The method involves preparing a slurry with the active materials, electrolyte, and additives, then blending in a solvent with a lower boiling point than the binder solvent. This mixture is applied to the battery components instead of the thicker binder slurry. The lower boiling solvent evaporates quickly during coating, reducing drying time and allowing higher packing density. The binder can be eliminated or reduced, improving performance by preventing particle aggregation over time.

Source

Electrode design for high energy density lithium-ion batteries with improved electrolyte impregnation. The electrode has an electrode mixture layer with inorganic particles dispersed on its surface. This increases electrolyte wetting and penetration compared to conventional electrodes. The particles are nanoscale and uniformly dispersed. They can also be mixed in the electrode slurry before coating. The particles are inorganic, such as silica or zirconia, and have an average size of 10 nm to 5 um. By dispersing particles on the electrode surface, it improves electrolyte impregnation for better battery performance.

Source

Preparing lithium-ion battery electrodes with vertical channels to improve ion transport efficiency. The method involves using a slurry with a specific composition that contains a thermal decomposition additive. The additive decomposes when the solvent evaporates, forming vertical channels in the electrode coating. This prevents the slurry from flowing and fills the channels with decomposition products. The result is a battery electrode with uniformly distributed vertical vent structures that facilitate ion transport compared to traditional disordered pores.

Source

High-viscosity slurry for cathode coating of lithium ion batteries that enables high-precision extrusion coating without agglomeration, and an extrusion coating method using this slurry. The slurry has a viscosity of 8000-50000 mPa·s, achieved by prolonged stirring of the cathode active material, conductive agent, and binder. This high viscosity enables consistent, dense coatings on battery cathodes using extrusion coating machines without agglomeration issues.

Source

Method to improve cycle stability and prevent capacity fade in lithium-ion batteries by controlling moisture content and viscosity during electrode slurry preparation. The method involves mixing the active material, conductive agent, and solvent in the first step to achieve a moisture content of 1000 ppm or less and viscosity of 500-8000 cP. In the second step, the slurry is kneaded to maintain the same moisture content. This reduces chemical damage to the active material during slurry preparation, resulting in better cycle stability and capacity retention in the final battery.

Source

Method for pre-lithium of lithium ion battery cathodes to improve their performance. The method involves adding inert lithium powder to a non-polar solvent to make a stable slurry. This slurry is then mixed into the electrode slurry to uniformly distribute the lithium powder. The slurry with the added lithium is rolled to break the lithium coating and enable direct contact between the lithium and the cathode. This improves the pre-lithiation effect compared to methods like direct mixing or spraying.

Source

Method to manufacture electrodes for lithium-ion batteries with improved adhesion between layers and reduced resistance. The method involves coating the electrode mixture twice, dividing it into a first coating with lower drying rate and a second coating with lower drying rate compared to the first. This allows the second coating to dry slower, reducing migration of binder polymer and improving adhesion between layers. The lower drying rate can be achieved by longer drying time or lower drying rate during constant-rate drying.

Source

Improving the quick charging performance of lithium batteries by optimizing the electrode slurry mixing process. The process involves using two dispersing agents, defoaming agents, and organic solvents in separate parts of the slurry to prevent caking, improve uniformity, and enhance quick charging. The first part of dispersing agent, defoaming agent, and organic solvent is used for the negative electrode slurry, while the second part is used for the positive electrode slurry. This hybrid mixing process helps prevent issues like caking, poor uniformity, and poor quick charging that can occur with conventional slurry mixing methods for lithium batteries.

Source

A method for preparing a positive electrode for lithium-ion batteries that improves battery performance. The method involves coating a current collector with two different active material slurries, one for a first active material and one for a second active material. The slurries are dried to form a semi-finished electrode sheet. The sheet is then pretreated in a lithium-containing electrolyte before drying to complete the electrode. The pretreatment step improves rate performance and capacity retention of the finished electrode compared to directly forming the electrode without pretreatment.

Source