3D Micro Current Collectors Using Laser DED for High-Capacitance Electrodes
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Solution Overview
Problem
Conventional methods for manufacturing 3D micro-supercapacitor current collectors are costly and time-consuming, and existing 3D printing techniques face challenges in directly printing on various substrates, limiting the production of high-aspect-ratio micro-metallic structures with high electrical conductivity and large surface areas.
Innovation Solution
The method employs laser direct energy deposition to print micro-metallic wires with a high aspect ratio onto substrates, followed by electroplating with reduced graphene oxide and polyaniline, enhancing the surface area and conductivity for improved capacitance in micro-supercapacitors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional multilayer coating techniques are used to create 3D microelectrode structures, then the structures can be manufactured, but the production time and cost increase significantly
Solution Approach 1:
The patent replaces conventional mechanical multilayer coating techniques with laser-based direct energy deposition (DED), an additive manufacturing process. This substitution enables direct fabrication of 3D microelectrode structures in a single step, eliminating the need for multiple coating layers and significantly reducing both manufacturing time and cost while maintaining high electrical conductivity and structural integrity
Solution Approach 2:
The patent changes the manufacturing parameters by transitioning from indirect multilayer coating to direct laser-based additive manufacturing. By controlling laser power, scanning speed, and deposition parameters, the process achieves high-aspect-ratio 3D structures with optimized electrical and mechanical properties, resolving the contradiction between ease of manufacture and productivity
2Adaptability or versatility
If SLA or SLM 3D printing methods are used to manufacture 3D microstructures, then the structures can be created, but direct printing onto various substrates becomes difficult
Solution Approach 1:
The patent employs laser-based direct energy deposition, which provides universal applicability across multiple substrate types including metals, ceramics, and polymers. The laser DED process can directly print micro-metallic wires and 3D structures onto various substrates without requiring substrate-specific process adjustments, thereby achieving both versatility and ease of manufacture simultaneously
Solution Approach 2:
The laser beam acts as an intermediary that enables direct printing onto diverse substrates. The laser energy melts and fuses metal powder with the substrate surface, creating strong bonding regardless of substrate material, thus overcoming the limitation of conventional 3D printing methods that struggle with substrate compatibility
3Productivity
If 2D electrode structures are used, then the manufacturing is simple, but the energy storage performance is limited due to geometric constraints
Solution Approach 1:
The patent transitions from 2D electrode structures to 3D microelectrode structures with high aspect ratios through laser-based direct energy deposition. This dimensional change increases the active surface area and volume for energy storage while the additive manufacturing process maintains manufacturing simplicity, thus improving energy storage performance without significantly increasing device complexity
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
This approach enables the cost-effective production of high-aspect-ratio micro 3D current collectors with enhanced electrical conductivity and surface area, significantly improving the capacitance of micro-supercapacitors through direct energy deposition and electroplating active materials.
Implementation Method 1
printing a plurality of micro wires on a substrate using laser direct energy deposition onto the substrate
Implementation Method 2
laser direct energy deposition
Implementation Method 3
Micro wires are electroplated with reduced graphene oxide and polyaniline
Data Source
AI summary
The present disclosure relates to a manufacturing method of a micro 3D current collector using laser direct energy deposition and a manufacturing method of a 3D electrode for a supercapacitor, particularly to a manufacturing method of a micro 3D current collector using laser direct energy deposition where micro-metallic structures are directly printed onto a substrate using a laser-based direct energy deposition process, and then used as the current collectors of the micro-supercapacitors. The current collector with printed micro-metallic wires possesses high electric conductivity and a high aspect ratio as well as a larger surface area due to the extensive surface area of the wires, making it suitable for depositing energy storage active materials.