3D Battery Base Impregnation With Flowing Solid Electrolyte Slurry
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Solution Overview
Problem
Conventional methods for manufacturing solid electrolyte layers in solid-state batteries face issues such as air entrapment, non-uniform composition, and increased manufacturing costs due to the use of natural convection for impregnation, leading to instability and higher material requirements.
Innovation Solution
A method and apparatus that involve positioning a base with a three-dimensional structure in an impregnation tank and feeding a flowing solid electrolyte slurry to uniformly impregnate the base, utilizing a pressure gradient and capillary action to prevent air entrapment and agglomeration, thereby reducing manufacturing costs and ensuring uniform composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If natural convection is used for impregnation, then handling and continuous productivity are improved, but air remains inside the base and impregnation time increases
Solution Approach 1:
The patent applies dynamics by introducing a circulating pump to create dynamic slurry circulation within the impregnation tank. The pump circulates the slurry in a predetermined direction, transforming the static natural convection system into a dynamic forced circulation system that actively removes air bubbles while maintaining continuous productivity.
Solution Approach 2:
The patent uses hydraulic principles by implementing a liquid circulation system with a pump to force slurry flow through the base material. This hydraulic approach replaces passive natural convection with active fluid circulation, enabling air removal without sacrificing production continuity.
2Device complexity
If natural convection is used for impregnation, then equipment complexity is reduced, but manufacturing cost increases due to larger slurry quantity required
Solution Approach 1:
The patent employs hydraulic circulation to efficiently distribute slurry throughout the base material. The pump-driven circulation system ensures complete slurry utilization by continuously moving the liquid through the porous structure, reducing waste and the need for excess slurry preparation.
Solution Approach 2:
The circulating pump maintains continuous slurry flow through the base material during impregnation. This continuous action ensures thorough penetration and uniform distribution of the slurry, maximizing material utilization and minimizing waste compared to batch-style natural convection methods.
3Device complexity
If no slurry flow is generated in the impregnation tank, then equipment complexity is reduced, but slurry composition becomes nonuniform and agglomeration occurs
Solution Approach 1:
The patent introduces dynamic slurry circulation using a pump to prevent stagnation and maintain uniform composition. The continuous movement of slurry prevents particle settlement and agglomeration, ensuring consistent impregnation quality without requiring complex additional mixing equipment.
Solution Approach 2:
The hydraulic circulation system created by the pump ensures uniform slurry distribution throughout the impregnation tank. The forced flow prevents localized concentration variations and agglomeration that would occur in static conditions, maintaining composition stability throughout the process.
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 and apparatus enable high-quality battery components to be produced efficiently and cost-effectively by ensuring uniform impregnation of the solid electrolyte, reducing air entrapment and agglomeration, and minimizing the need for excess slurry, thus stabilizing the manufacturing process.
Implementation Method 1
impregnating the base with a slurry of solid electrolyte in an impregnation tank that can contain the slurry of solid electrolyte by using capillary action
Implementation Method 2
feeding a solid electrolyte slurry to the base positioned in the impregnation tank while keeping the solid electrolyte slurry flowing
Data Source
AI summary
Provided are a method and an apparatus for manufacturing a battery component including a base having a three-dimensional structure at low manufacturing costs, the method and the apparatus enabling impregnation of the base with a solid electrolyte of uniform composition while preventing or inhibiting air from remaining inside the base. A method of manufacturing a battery component, including: a first step of positioning a base having a three-dimensional structure in an impregnation tank; and a second step of feeding a solid electrolyte slurry to the base positioned in the impregnation tank while keeping the solid electrolyte slurry flowing, thereby impregnating the base with the solid electrolyte slurry.