Mixing & Coating Technology for EV Battery Electrodes

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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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Simplified and efficient method for manufacturing multilayer electrodes for secondary batteries that reduces complexity and prevents issues like mixing and alignment errors compared to coating and stacking individual layers. The method involves injecting and applying two slurries containing different active materials and solvents in a single coating device to simultaneously form multiple active material layers on the electrode. The solvents have different properties to prevent intermixing and allow forming a layered structure.

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Coating method for ternary positive electrode sheets in lithium-ion batteries to improve energy density, cycle life, and rate capability. The coating involves spray depositing a mixture of ternary electrode material, conductive agent, and binder onto the current collector using electrostatic spraying. This forms a compact electrode sheet with uniform particle distribution, minimized agglomeration, and better interface contact compared to wet methods.

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High solids content electrode pastes for batteries that enable faster drying and improved coating uniformity compared to conventional slurry coating methods. The paste formulations contain active materials, binders, solvents, and hyperdispersants with specific viscosities optimized for the coating tool. The high solids content allows thicker coatings to be applied without cracking, as the paste maintains shape during drying. The thicker coatings dry faster and provide better coating uniformity compared to thin coatings. The thicker coating also reduces the need for calendering and cutting steps. The pastes can be used for electrode fabrication or as sintered substrates for battery cells. The paste composition allows electrode thicknesses as low as 5 microns for thin-film batteries or as high as 300 microns for thicker electrodes.

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Method for producing a paste for making electrodes for batteries and capacitors that reduces production time and prevents particle clogging. The method involves charging powder materials with different specific surface areas into a mixing container in a specific order. First, the electrode active material is added, then the conductive additive with higher surface area, and finally the thickener. This prevents coarse particles from forming during mixing that could clog filters or create lumps in the paste.

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