3D Printed Thick Electrodes for High-Capacity Battery Transport
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Solution Overview
Problem
Existing lithium-ion batteries face challenges in achieving higher capacity, faster charge-discharge rates, and lower costs, particularly due to limitations in electrode thickness, ionic and electronic transport, and energy capacity.
Innovation Solution
The development of 3D printed batteries using rheologically-tailored electrode ink formulations that include dispersed electroactive particles and conductive particles, allowing for the creation of thick, biphasic semi-solid electrodes with enhanced ionic and electronic transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electrode thickness is increased to improve energy capacity, then areal energy density increases, but ionic and electronic transport becomes more difficult reducing power density
Solution Approach 1:
The electrode is segmented into a hierarchical 3D structure with macroscopic thickness divided into microscopic conductive pathways. Conductive particles form interconnected networks that segment the transport path into multiple parallel channels, allowing ions and electrons to travel shorter distances through the thick electrode, thus maintaining high power density while achieving high energy capacity.
Solution Approach 2:
The invention transitions from 2D planar electrodes to 3D volumetric electrodes with complex architectures. By adding the third dimension and creating folded, stacked, or interdigitated structures, the electrode achieves high areal energy density while maintaining short transport distances through the conductive particle networks that span the volumetric structure.
2Productivity
If conventional battery architectures are used to maintain simple manufacturing, then fabrication complexity remains low, but capacity and charge-discharge rates are limited
Solution Approach 1:
The invention changes the fundamental parameters of electrode architecture from thin 2D layers to thick 3D structures with controlled porosity and conductive networks. By adjusting parameters such as particle size distribution, volume fractions of active vs. conductive materials, and hierarchical pore structures, the electrode achieves both high charge-discharge rates and complex functionality.
Solution Approach 2:
The electrode is formulated as a composite material system containing electroactive particles, conductive particles, binders, and electrolytes in specific ratios. This composite structure enables simultaneous optimization of energy storage (electroactive particles), electron transport (conductive particles), and ion transport (electrolyte-filled pores), achieving high productivity without excessive manufacturing complexity.
3Quantity of substance
If thick electrodes are used to increase volumetric ratio of active to inactive materials, then energy capacity improves, but ionic and electronic transport through the electrode is significantly reduced
Solution Approach 1:
The electrode exhibits local quality variations with different regions optimized for different functions. The outer regions contain higher concentrations of conductive particles for efficient electron collection, while inner regions maximize active material content for energy storage. This spatial differentiation of material properties enables thick electrodes to maintain both high active material ratios and efficient transport.
Solution Approach 2:
The conductive particle networks form curved, three-dimensional pathways throughout the thick electrode structure, replacing straight linear paths. These curved conductive highways wind through the volumetric electrode, providing multiple routes for electron transport that accommodate the thick geometry while maintaining short effective transport distances and high transport efficiency.
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 3D printed batteries exhibit a ten-fold higher areal capacity compared to previous designs, with thick electrodes maintaining high electronic conductivity and achieving superior areal energy density while retaining areal power density.
Implementation Method 1
rheologically-tailored electrode ink formulations that include dispersed electroactive particles and conductive particles
Implementation Method 2
A separator ink formulation is then extruded through a second deposition nozzle moving relative to the substrate, and one or more continuous filaments comprising the separator ink formulation are deposited in a predetermined pattern to print a separator on the first electrode
Implementation Method 3
A first electrode ink formulation is then extruded through a first deposition nozzle moving relative to the substrate, and one or more continuous filaments comprising the first electrode ink formulation are deposited in a predetermined pattern to print a first electrode
Data Source
AI summary
A method of 3D printing a battery includes extruding a first electrode ink formulation through a first deposition nozzle moving relative to a substrate, and depositing one or more continuous filaments comprising the first electrode ink formulation on the substrate to print a first electrode. A separator ink formulation is extruded through a second deposition nozzle moving relative to the substrate, and one or more continuous filaments comprising the separator ink formulation is deposited on the first electrode to print a separator precursor, which is then cured to form a separator. A second electrode ink formulation is extruded through a third deposition nozzle moving relative to the substrate, and one or more continuous filaments comprising the second electrode ink formulation is deposited to print a second electrode on the separator. The first and second electrodes and the separator are enclosed in a package, thereby forming a battery with thick electrodes.