Carbon Nanotube-Polymer Powder for Low-Solvent Electrode Dispersion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for formulating electrodes with carbon nanotubes require large amounts of solvent, leading to a high carbon footprint and suboptimal electrical performance compared to solvent-based dispersions.
Innovation Solution
A carbon nanotubes-polymer composition in powder form with specific density, porosity, and solvent content, allowing for effective redispersion and achieving electrical performance equivalent to solvent-based routes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If carbon nanotubes are dispersed in a liquid form comprising a solvent, then the carbon nanotubes are released from their entanglements and can be formulated, but large amounts of solvent are required leading to a very unfavorable carbon footprint
Solution Approach 1:
The invention changes the physical state parameter of the composition from liquid to dry powder form, eliminating the need for large amounts of solvent while maintaining the dispersion quality through controlled porosity and density parameters of the powder
Solution Approach 2:
The invention utilizes a porous powder structure with controlled porosity (0.4-0.8 cm³/g) that allows the powder to redispersion effectively in liquid media while minimizing the amount of solvent needed for transport and formulation
2Loss of substance
If carbon nanotubes are transported in dry form with high content, then the carbon footprint is minimized, but the electrical performance of the resulting electrodes is suboptimal compared to solvent-based dispersions
Solution Approach 1:
The invention optimizes multiple parameters of the dry powder including bulk density (0.1-0.5 g/cm³), porosity (0.4-0.8 cm³/g), and particle size distribution to achieve both minimal solvent content and optimal electrical performance equivalent to solvent-based dispersions
Solution Approach 2:
The invention creates a composite powder material combining carbon nanotubes with specific polymers in controlled ratios, where the polymer matrix maintains the nanotube dispersion structure in the dry state and enables effective redispersion while preserving electrical conductivity
3Ease of manufacture
If carbon nanotubes are formulated in entangled bundles or balls, then they can be handled in powder form, but the relative density is too low and the formulations do not exhibit the expected improvements in electrical conduction
Solution Approach 1:
The invention transforms the aggregate structure of carbon nanotubes from entangled bundles to a controlled porous powder morphology with optimized bulk density and particle size, enabling both easy handling and effective electrical conduction through improved surface area and dispersion
Solution Approach 2:
The invention employs a porous powder structure that prevents re-entanglement of nanotubes while maintaining low bulk density for easy handling, with the porosity enabling better solvent penetration and redispersion for optimal electrical performance
Data Source
AI summary
The present invention relates to compositions of carbon nanotubes which can be used in solid form, that is to say in the absence of solvent. These compositions comprise at least one polymer and are readily dispersible in formulations for the manufacture of electrodes for batteries and in particular Li-ion batteries in liquid or solid processes. The invention also relates to the process for obtaining these powders, to their use in the manufacture of electrodes for batteries, and also to the batteries comprising them.