3D Lithium Battery Printing With Conformal Porous Separator Layers
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Solution Overview
Problem
Current methods for manufacturing lithium batteries lack the precision and conformality to effectively form three-dimensional electrochemical batteries, including anode, cathode, and separator layers, with aerosol jet printing not previously utilized for their entirety.
Innovation Solution
Aerosol jet printing process is employed to form three-dimensional electrochemical lithium batteries by aerosolizing ink formulations containing nanoparticles or microparticles of active materials and binders, with a permeable separator layer created using polymer precursors and activating radiation sources to achieve high conformality and desired porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for lithium batteries, then production efficiency is maintained, but manufacturing precision and conformality for three-dimensional structures are insufficient
Solution Approach 1:
The battery is divided into discrete layers (anode, cathode, separator, current collectors) that are manufactured separately using aerosol jet printing and then assembled. This segmentation enables precise control of each layer's properties while maintaining production efficiency through modular manufacturing.
Solution Approach 2:
The patent transitions from conventional two-dimensional planar battery structures to three-dimensional architectures using aerosol jet printing. This dimensional change enables complex curved and three-dimensional battery designs while maintaining manufacturing precision through the printing process's inherent conformality.
2Manufacturing precision
If aerosol jet printing is used to form battery layers, then manufacturing precision and conformality are improved, but production time increases
Solution Approach 1:
The aerosol jet printing process prepares each battery layer with precise thickness and material distribution before assembly. This preliminary action ensures that layers are pre-optimized for their specific functions, reducing the need for post-processing and adjustments during assembly, thereby mitigating time losses.
Solution Approach 2:
The patent optimizes printing parameters such as aerosol flow rate, substrate temperature, and printing speed to balance manufacturing precision with production efficiency. By adjusting these parameters, the process achieves high conformality while minimizing manufacturing time through optimized deposition rates.
3Manufacturing precision
If aerosol jet printing is used for battery fabrication, then precision in layer formation is improved, but process complexity increases
Solution Approach 1:
The aerosol jet printing system is designed to manufacture multiple different battery layers (anode, cathode, separator, current collectors) using the same equipment and process. This universality reduces the need for multiple specialized manufacturing systems, thereby managing process complexity while maintaining high precision across all layer types.
4Manufacturing precision
If conventional methods are used for separator layer formation, then porosity is achieved, but conformality and precision are insufficient
Solution Approach 1:
The patent replaces conventional mechanical separator fabrication methods with aerosol jet printing. This substitution enables precise control of separator layer thickness, porosity, and conformality through digital printing parameters, while maintaining ease of manufacture through a single-step direct printing process that eliminates multiple mechanical processing steps.
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 process enables the fabrication of lithium batteries with improved performance and stability, comparable to conventional methods, with enhanced conformality and precision in layer formation, allowing for integration into complex substrates and maintaining electrochemical integrity.
Implementation Method 1
aerosolizing ink formulations containing nanoparticles or microparticles of active materials and binders
Implementation Method 2
via ultrasonic or pneumatic means, to produce droplets on the order of one to two microns in diameter
Implementation Method 3
exposing the aerosolized polymer precursor solution to a first activating radiation source to form partially cured polymer spheres
Implementation Method 4
Electrochemical batteries are chemical storage systems that interconvert chemical energy and electrical energy through redox reactions of cathode and anode materials
Implementation Method 5
The ions move from the anode and pass through the electrolyte until they reach the cathode
Data Source
AI summary
A method of manufacturing a three-dimensional electrochemical lithium battery includes forming a first electrode on an underlying layer comprising aerosolizing a first ink formulation comprising a slurry including nanoparticles or microparticles of a first active material and a binder, and depositing the slurry onto the underlying layer to form a first electrode layer. A permeable separator layer is formed on the first electrode by aerosolizing a polymer precursor solution, exposing the aerosolized polymer precursor solution to a first activating radiation source to form partially cured polymer spheres in the aerosolized stream, focusing and directing the aerosolized stream onto a substrate to form the permeable separator layer of the partially cured polymer spheres, and exposing the partially cured polymer spheres on the substrate to a second activating radiation source to fully cure the partially cured polymer spheres. A second electrode is formed on the permeable separator layer by aerosolizing a second ink formulation comprising a slurry including nanoparticles or microparticles of a second active material and a binder, and depositing the slurry onto the permeable separator layer.