Alkali Metal Current Collector Coating With Integrated Purification
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Solution Overview
Problem
Existing methods for manufacturing alkali metal coated current collectors are complex and require significant space, making them inefficient and cumbersome.
Innovation Solution
A streamlined method and apparatus for manufacturing alkali metal coated current collectors involve melting alkali metal in an inert atmosphere, removing impurities, and applying the purified metal directly to current collector substrates using a vertically moving substrate and a temperature-controlled zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used for manufacturing alkali metal coated current collectors, then the process can be completed, but the process complexity and space requirements increase significantly
Solution Approach 1:
The patent combines multiple separate operations (melting, impurity removal, coating application) into a single integrated apparatus. The melt chamber serves both as the heating zone and the coating application point, eliminating the need for separate transport mechanisms and reducing overall system complexity.
Solution Approach 2:
The dispensing chamber and melt chamber are designed to perform multiple functions: heating, melting, impurity separation, and direct coating application. This multi-functionality reduces the number of separate components needed in the system.
2Ease of manufacture
If traditional methods are used for manufacturing alkali metal coated current collectors, then the process can be completed, but the space requirements increase significantly
Solution Approach 1:
The coating application process is nested within the melt chamber space. The substrate passes directly through the dispensing opening into the melt chamber area, allowing coating to occur within the existing thermal zone rather than requiring a separate application chamber.
Solution Approach 2:
The substrate is fed vertically through the dispensing chamber, utilizing the vertical dimension for the coating process. This eliminates the need for horizontal transport mechanisms and reduces the horizontal footprint of the apparatus.
3Productivity
If impurities are not removed from melted alkali metal, then the coating process can proceed faster, but the product quality deteriorates
Solution Approach 1:
Impurity removal is performed preliminarily within the melt chamber before the coating material is dispensed. The floating impurities are removed from the melted alkali metal while it is being maintained at coating temperature, ensuring clean coating material is available for immediate application.
4Device complexity
If the current collector substrate does not move vertically through the dispensing chamber, then the equipment can be simpler, but the coating application efficiency decreases
Solution Approach 1:
The substrate feed mechanism is designed to move the substrate vertically through the dispensing chamber at a controlled rate. This dynamic positioning allows continuous coating application while maintaining proper alignment with the melt chamber opening.
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 solution simplifies the production process, reduces space requirements, and ensures a more efficient application of alkali metal, resulting in improved manufacturing efficiency and product quality.
Implementation Method 1
a heater for melting alkali metal in the melt chamber
Implementation Method 2
The apparatus can include a temperature-controlled zone to condition the coated substrate
Data Source
AI summary
A method of manufacturing an alkali metal coated current collector for a battery, the method includes melting the alkali metal, removing impurities floating on the surface of the melted alkali metal; applying the purified melted alkali metal to the surface of at least one side of a passing current collector substrate to form a coating on the current collector substrate. A system for manufacturing an alkali metal coated current collector for a battery includes at least one extruder having a melt chamber, an inlet extending to the melt chamber, at least one feed roller in the inlet for feeding alkali metal introduced into the inlet to the melt chamber; a heater for melting alkali metal in the melt chamber; an opening in the chamber for removing impurities floating on the melted alkali metal in the melt chamber; an outlet extending from the melt chamber to a dispensing opening; a reservoir for receiving melted alkali metal; and at least one drive roller for driving a current collector substrate past the reservoir to receive a coating of melted alkali metal.