High-Consistency Cellulose Composites for Flexible Energy Storage
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Solution Overview
Problem
Existing methods for manufacturing cellulose-based composites and energy storage devices face challenges in achieving efficient energy storage, optimal electrode contact, and flexible, lightweight structures, often requiring complex lamination and high drying energy.
Innovation Solution
The use of high consistency fibrillated cellulose mixed with functional additives like graphite and graphene, processed to form composite structures with high solids content, allowing for easier shaping and drying, and enabling the creation of flexible and wearable energy storage devices with improved mechanical and electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If low consistency cellulose suspension is used, then the mixture is easy to process and shape, but the drying energy requirement increases and manufacturing efficiency decreases
Solution Approach 1:
The patent changes the consistency parameter of cellulose suspension from low (conventional) to high (20-50% solids content), fundamentally altering the processing characteristics. This parameter change enables the slurry to be molded directly at high solids content, eliminating the need for extensive drying and significantly reducing energy consumption while maintaining ease of shaping.
Solution Approach 2:
The patent applies different consistency levels to different stages of manufacturing: high consistency (20-50%) for the molding stage to minimize drying, and controlled water content (up to 80%) for the final product requirements. This local optimization of consistency at each manufacturing stage resolves the contradiction between ease of processing and drying energy.
2Reliability
If complex lamination processes are used, then electrode contact can be optimized, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent merges multiple manufacturing steps into a single integrated process. By formulating a high-consistency slurry containing cellulose, functional additives, and binding agents that provides both structural integrity and electrode contact, the invention eliminates the need for separate lamination steps, reducing device complexity while maintaining reliable electrode contact.
Solution Approach 2:
The patent uses composite materials comprising cellulose fibers combined with functional additives and binding agents in a high-consistency slurry. This composite formulation provides both the mechanical structure and the electrode contact functionality in a single material system, eliminating the need for complex multi-layer lamination processes.
3Use of energy by stationary object
If high solids content mixture is used, then drying energy is reduced and manufacturing efficiency improves, but the mixture becomes harder to process and shape
Solution Approach 1:
The patent optimizes the solids content parameter to a specific range (20-50%), which is high enough to reduce drying energy but low enough to maintain processability. This precise parameter control resolves the contradiction by finding the optimal balance point where the slurry is sufficiently concentrated to minimize drying while remaining workable for molding operations.
Solution Approach 2:
The patent introduces binding agents as intermediary substances that facilitate processing of high-consistency slurries. These binding agents act as mediators between the cellulose fibers and the molding process, enabling the high-solids mixture to be shaped and formed without requiring low consistency, thus resolving the contradiction between high solids content and ease of processing.
4Productivity
If conventional manufacturing methods are used, then existing processes can be maintained, but energy efficiency and manufacturing simplicity are compromised
Solution Approach 1:
The patent exploits the phase transition characteristics of water evaporation at high solids content. By concentrating the slurry to 20-50% solids before molding, the amount of water requiring phase transition (evaporation) is minimized, dramatically reducing the energy consumption associated with this phase change while improving manufacturing efficiency through direct molding of the concentrated slurry.
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 simplifies the manufacturing process, reduces internal losses, and allows for the production of lightweight, flexible energy storage devices with optimal electrode contact and superior mechanical properties, suitable for mobile and structural applications.
Implementation Method 1
The high consistency mixture is processed to form the composite structure having a shape
Implementation Method 2
The high consistency mixture is processed to form the composite structure having a shape and then dried or let to dry
Data Source
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AI summary
Document discloses new technologies for utilizing cellulose based materials in composites and electrically functionalised structures,such as energy storage devices. The object of the invention is achieved by means of high consistency fibrillated cellulose with at least one functional additive. This high consistency mixture is processed to form the composite structure having a shape and then dried or let to dry.