Battery Electrode Coatings With LIFT-Printed Rough Surface Architecture

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Solution Overview

Problem

Current battery component manufacturing processes lack the ability to produce alternative architectures and consistently high-quality components with desired surface roughness and electrochemical performance.

Innovation Solution

The use of a laser-induced forward transfer (LIFT) printing technique to deposit material pixels on a current collector, creating a coating with specific surface roughness and architecture that includes a first surface with a maximum height of over 60 micrometers, a maximum peak height of over 40 micrometers, and an arithmetical mean height of over 10 micrometers, while maintaining high electrochemical performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional battery component manufacturing processes are used, then production is achieved with standard component architectures, but the ability to produce alternative architectures and consistently high-quality components with desired surface roughness is limited

Engineering Contradiction:

Improveability to produce alternative architecturesVSAvoidsurface roughness control

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The LIFT printing process enables precise control of surface roughness parameters (Sz > 60 μm, Sp > 40 μm, Sa > 10 μm) by adjusting processing parameters such as laser energy density, pulse duration, and material layer thickness. This allows production of electrodes with tailored surface characteristics that enhance electrochemical performance while maintaining manufacturing versatility for different architectures

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The electrode coating is formed by depositing material pixels in an overlapping pattern, creating a segmented yet continuous structure. This pixel-based approach enables precise control over surface topology and architecture while maintaining coating integrity, allowing production of both traditional and alternative electrode architectures

Inventive Principle:

Principle #1Segmentation

2Reliability

If surface roughness is increased to enhance electrochemical performance, then specific capacity and columbic efficiency improve, but manufacturing complexity increases

Engineering Contradiction:

Improveelectrochemical performanceVSAvoidsurface structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The LIFT printing technique replaces conventional mechanical coating methods with a laser-based energy transfer process. This substitution enables precise control of surface roughness and material distribution without complex mechanical tooling, achieving enhanced electrochemical performance (specific capacity 168-178 mAh/g, columbic efficiency 99%) through energy-field interaction rather than mechanical means

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electrode coating exhibits a porous, pixel-based structure with controlled void spaces between material deposits. This porous architecture increases surface area and facilitates electrolyte penetration, enhancing electrochemical performance while the regular pixel pattern maintains manufacturing simplicity through systematic material deposition

Inventive Principle:

Principle #31Porous materials

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 method enables the production of battery components with enhanced surface roughness and electrochemical performance, achieving a minimum specific capacity of 168 to 178 mAh/g and columbic efficiency of 99% without negatively affecting the electrochemical performance, and allows for the production of components with varied surface features and architectures.

Implementation Method 1

generating a laser beam having a wavelength, wherein the donor substrate is substantially transparent at the wavelength of the laser beam, directing, with a processor of a controller, the laser beam toward the donor substrate such that the laser beam passes through the donor substrate and is focused on an interface between the donor substrate and the donor layer, irradiating the donor layer with the laser beam to cause portions of the donor layer to eject and contact the receiving substrate to form material pixels thereon

Methodology Applied

Scientific EffectLaser-induced forward transfer (LIFT): Laser Ablation

Data Source

PatentUS20240304793A1Electrodes and batteries comprising the same

Publication Date: 2024.09.12 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

Electrodes and batteries comprising such electrodes are provided. The electrodes include a current collector, and a coating on the current collector. The coating includes more than one layer that includes an active material. The coating also includes a first surface facing away from the current collector that has a maximum height (Sz) surface roughness of greater than 60 micrometers (μm), a maximum peak height (Sp) surface roughness of greater than 40 micrometers (μm), and an arithmetical mean height (Sa) surface roughness greater than 10 micrometers (μm).