3D Electrode Co-Extrusion With Rotating Dies for Faster Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrode manufacturing processes are time-consuming, costly, and environmentally hazardous, with secondary processes adding significant costs and risks, and there is a need for improved methods to achieve high energy density, low internal resistance, and efficient manufacturing of 3D-electrodes.
Innovation Solution
A device and method for co-extruding electrodes using a rotating die that integrates multiple manufacturing steps into a single process, allowing for the creation of 3D-shaped electrodes with macro-, micro-, and nano-patterns, enhancing electrochemical surface areas, and reducing the need for secondary processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional extrusion methods with secondary processes are used, then electrodes can be manufactured, but manufacturing time and costs increase significantly
Solution Approach 1:
The patent combines multiple secondary processes (calendaring, etching, laser printing, plasma treatment) into a single integrated extrusion process. The rotating die with circumferential structures performs both forming and surface patterning in one operation, eliminating sequential processing steps and reducing manufacturing time.
Solution Approach 2:
The rotating die serves multiple functions simultaneously: it acts as both the extrusion die for shaping the electrode and as the patterning tool for creating macro-, micro-, and nano-structures on the electrode surface. This multi-functionality eliminates the need for separate specialized equipment for each process.
2Manufacturing precision
If multiple secondary processes are applied to extruded electrodes, then electrode performance is improved, but manufacturing costs increase
Solution Approach 1:
The patent integrates multiple process functions into a single extrusion device. The rotating die combines shaping and surface patterning functions, eliminating the need for separate calendaring machines, etching equipment, laser systems, or plasma treatment apparatus, thereby reducing device complexity while maintaining precision.
Solution Approach 2:
The rotating die is segmented into different circumferential zones with different structures (macro-patterns, micro-patterns, nano-patterns), allowing each zone to perform a specific patterning function. This segmentation enables complex surface structures to be created through a single integrated process rather than multiple sequential processes.
3Manufacturing precision
If chemicals are used in secondary processes, then electrode surface treatment is achieved, but environmental hazards increase
Solution Approach 1:
The patent replaces chemical treatment processes (etching, plasma treatment) with a purely mechanical process. The rotating die with circumferential structures physically imprints the surface patterns onto the electrode material during extrusion, eliminating the need for hazardous chemicals while achieving the same surface treatment objectives.
4Ease of manufacture
If thinner electrodes are manufactured, then cost is reduced, but energy density and charging performance may be compromised
Solution Approach 1:
The patent creates 3D-electrodes with complex surface topographies including macro-, micro-, and nano-structures. This dimensional complexity increases the effective surface area and porosity of thin electrodes, allowing them to achieve high energy density and fast charging performance despite reduced thickness. The volumetric energy density is improved through the three-dimensional architecture created by the rotating die patterns.
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 method enables efficient production of electrodes with increased surface area and improved energy density, reducing manufacturing time and costs while minimizing environmental impact and risks.
Implementation Method 1
the first rotating die is rotatable about an axis extending across the production direction and arranged to allow the outer circumferential surface to, while the first rotating die rotates, exert a pressure onto a surface of the electrode material when fed through the profile definition zone
Implementation Method 2
the second channel section is configured to deform the electrode material into the electrode product having a minimum height
Implementation Method 3
A device and method for co-extruding electrodes using a rotating die integrates multiple manufacturing steps into a single process
Data Source
AI summary
The disclosed invention refers to a device and a method for 3D-extruding electrodes that are useful for electrochemical reactions or energy storage in batteries, secondary batteries, capacitors or fuel cells. The described method solves problems of time and cost-consuming steps, by integrating many steps into one step, by co-extruding with rotating dies onto a base profile, enabling elimination of at least one production step at the same time as it enables extrusion of electrodes with macro-, micro-, and/or nano-patterns, thus enabling bigger electrochemical reaction surfaces and cross-channels that speed-up filling of electrolyte.