Cathode Electrode Voxel Printing for Surface Geometry Control

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Solution Overview

Problem

Conventional methods for creating cathode electrodes for electric vehicle batteries face challenges in achieving high reproducibility and controlling surface geometry, particularly due to limitations in roll-to-roll processes and additive manufacturing techniques such as extrusion or ink-jet printing, which struggle with material properties like viscosity and particle size.

Innovation Solution

The Electrode Laser Induced Forward Electrode Transfer (eLIFT) process and formulations allow for the creation of unique surface geometries and densities, enabling the production of cathode electrodes with enhanced control over surface roughness and geometry through customized combinations of eLIFT printing parameters and cathode formulations, facilitating high-speed deposition and improved reproducibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If roll-to-roll processes are used to create cathode electrodes, then high-speed deposition is achieved, but control over surface geometry and reproducibility deteriorates

Engineering Contradiction:

Improvedeposition speedVSAvoidsurface geometry control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The continuous electrode material is divided into discrete voxel units through laser-induced forward transfer, allowing individual control of each segment's geometry while maintaining high-speed processing through automated laser scanning

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical roll-to-roll deposition system is replaced with a laser-based energy field system that uses optical energy to transfer material, enabling precise geometric control without mechanical contact while maintaining high throughput

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If additive manufacturing processes such as extrusion or ink-jet printing are used, then material property control is improved, but manufacturing complexity and limitations increase

Engineering Contradiction:

Improvematerial property controlVSAvoidprocess limitations

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The laser pulse parameters (energy, duration, frequency) are dynamically adjusted to control material transfer, eliminating the need for complex rheological control of materials required by extrusion and ink-jet processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

A transparent carrier substrate serves as an intermediary that holds the cathode material in a dispensable configuration, allowing laser-induced transfer without direct mechanical manipulation of the material itself

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If conventional methods are used to create cathode electrodes, then manufacturing simplicity is maintained, but surface geometry control and reproducibility deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidsurface geometry control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Conventional mechanical deposition methods are replaced with laser-induced forward transfer using a transparent carrier substrate, maintaining manufacturing simplicity while achieving superior surface geometry control through non-contact material transfer

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser beam delivers energy locally to specific regions of the cathode material on the carrier substrate, enabling precise control of material transfer at each location while maintaining overall process simplicity

Inventive Principle:

Principle #3Local quality

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 eLIFT process enables the production of cathode electrodes with precise control over surface geometry and density, leading to improved electrochemical properties and increased potential for high-speed deposition, addressing the limitations of conventional methods.

Implementation Method 1

an optical system configured to generate a laser beam through the donor foil and the transparent carrier substrate to create a plurality of cathode voxels

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

The present disclosure applies an Electrode Laser Induced Forward Electrode Transfer (eLIFT) process

Methodology Applied

Scientific EffectLaser Induced Forward Transfer: Laser Ablation

Data Source

PatentUS20250100075A1Systems and methods for method for creating a cathode electrode product for a battery system of an electric vehicle

Publication Date: 2025.03.27 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A system comprises a donor foil, a carrier substrate disposed adjacent the donor foil, an optical system configured to generate a laser beam through the donor foil and the carrier substrate to create a plurality of cathode voxels, and a current collector foil defined by an X-Y plane and configured to collect the plurality of cathode voxels in the X-Y plane, wherein a first set of the plurality of cathode voxels at a first location on the X-Y plane are diluted with a first amount of a solvent and a second set of the plurality of cathode voxels at a second location on the X-Y plane are diluted with a second amount of a solvent, the second amount of the solvent being less than the first amount of the solvent.