Treated Carrier Foil Lamination for Dense Solid-State Electrodes
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Solution Overview
Problem
Current lithium-based rechargeable battery electrode manufacturing processes are inefficient and prone to flaws, leading to shorter battery life and potential shorts due to high porosity and delicate layer handling issues, particularly with carbon-based anodes and traditional liquid electrolytes.
Innovation Solution
The method involves using a treated carrier foil with surface energy to adhere and densify solid-state electrolyte layers during the manufacturing of battery electrodes, allowing for efficient lamination and peeling without damaging the layers, and employing a calender press and peeling device to reduce porosity and enhance material contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing processes are used for battery electrodes, then production can proceed with conventional methods, but the battery life is shortened and potential shorts occur due to high porosity and layer damage
Solution Approach 1:
A carrier foil is introduced as an intermediary element during the manufacturing process. The solid-state electrolyte layer is cast onto this carrier foil, which provides mechanical support during handling and densification. The carrier foil acts as a temporary substrate that maintains layer integrity throughout processing, preventing the high porosity and layer damage that occur with conventional methods. After densification, the carrier foil is peeled away, leaving a dense, intact electrode layer with improved reliability and reduced shorts.
2Reliability
If solid-state electrolyte layers are handled delicately during manufacturing, then layer damage is reduced, but production efficiency decreases
Solution Approach 1:
The carrier foil serves as a mediator that enables efficient manufacturing while maintaining layer integrity. By casting the solid-state electrolyte onto the carrier foil and then densifying the entire assembly, the process achieves both delicate layer handling and high production efficiency. The carrier foil allows for mechanical densification without direct handling of the fragile electrolyte layer, and the subsequent peeling step is a simple, fast operation that does not significantly impact productivity.
Solution Approach 2:
The carrier foil is prepared in advance with appropriate surface properties before the solid-state electrolyte is cast onto it. This preliminary preparation ensures that the electrolyte layer adheres properly to the carrier during manufacturing but can be easily peeled away afterward. The surface treatment or selection of carrier foil material is done beforehand, enabling smooth manufacturing operations without compromising layer adherence or production efficiency.
3Reliability
If porosity is reduced through densification, then battery reliability improves, but the manufacturing process becomes more complex
Solution Approach 1:
The carrier foil simplifies the densification process by providing a rigid substrate that supports the solid-state electrolyte layer during compression. Instead of attempting to densify a loose, porous layer directly (which would require complex multi-step processes), the electrolyte is cast onto the carrier foil first, creating a pre-formed structure that can be densified in a single, straightforward compression step. The carrier foil distributes the densification pressure evenly and prevents layer deformation, achieving high electrode density with a simple manufacturing 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
This approach improves the reliability and efficiency of battery electrode production by ensuring proper adhesion and densification of solid-state electrolyte layers, reducing the risk of layer damage and enhancing the integrity of the electrode stack, thus extending battery life and preventing shorts.
Implementation Method 1
a treated carrier foil having a surface energy adjacent to the dried electrode layer, and densifying the electrode layer by applying a densifying pressure to the dried electrode layer, wherein the surface energy adhering the dried electrode layer to the treated carrier foil retains the adherence of the dried electrode layer to the treated carrier foil following densification
Implementation Method 2
employing a calender press and peeling device to reduce porosity and enhance material contact
Implementation Method 3
employing a calender press and peeling device to reduce porosity and enhance material contact
Data Source
AI summary
Aspects of the present disclosure involve utilizing layers, such as an outer carrier foil layer, that provide a surface energy sufficient to prevent separation of the layers of the stack during lamination while allowing for the proper densification of the solid-electrolyte separator layer. In one particular example, a Corona-treated or carbon coated outer foil layer may be used during manufacturing of the electrode stack that provides a sufficient surface energy to adhere to the solid-electrolyte separator layer during the lamination process, while allowing for subsequent peeling of the Corona-treated outer foil from the electrode stack after densification without damaging the remaining layers of the stack. The electrode laminate discussed herein may be utilized in any type of battery or electrochemical cell, including solid, semi-solid, or liquid-based batteries.