Method for Manufacturing Dry Electrode for Secondary Battery and Secondary Battery Electrode Manufactured Thereby

Solvent-Free Hot-Pressed Dry Electrode with CNT Scaffolds Anchored in Etched Current Collector Pores

This technology utilizes a solvent-free dry process to manufacture electrodes by hot-pressing multi-walled carbon nanotubes (MWCNTs) and binders into a 3D scaffold network on the surface of a current collector featuring sub-micron etched pores.

Wet processes rely on NMP, a hazardous solvent that increases environmental impact and costs. Existing dry processes often suffer from poor electrode adhesion, leading to delamination, brittleness, structural instability under high-loading conditions, and reduced rate performance.

This technology involves placing a MWCNT and PVDF composite, mixed via vortex mixer, onto a metal current collector with 50–1000 nm wide etched pores created through oxidation, followed by hot-pressing at 160–200°C and 8–12 MPa. The carbon nanotube scaffold is physically anchored within the etched pores, significantly enhancing electrode adhesion and electrical networking. Applicable to cathode production lines that require costly NMP recovery systems and high-loading lithium-ion or sodium-ion batteries, this method enables the production of delamination-resistant, thick electrodes in seconds without hazardous solvents.

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Key Features:

• Placing a current collector with 50 to 1000 nm wide etched pores formed by oxidation onto the lower metal plate of a hot press.
• Preparing an electrode powder mixture by pulverizing, mixing, and drying an electrode active material, a carbon nanotube conductive agent, and a binder.
• Loading the electrode powder mixture onto the surface of the etched current collector to form an electrode powder layer.
• Placing an upper metal plate on the electrode powder layer and hot-pressing at 160 to 200°C and 8 to 12 MPa to form a dry electrode.

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