Carbon Nanotube-Polymer Powder for Low-Solvent Battery Electrodes
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Solution Overview
Problem
Current methods for formulating electrodes with carbon nanotubes either result in suboptimal electrical performance when using a dry route or require transporting large quantities of solvent-based dispersions, leading to an unfavorable carbon footprint.
Innovation Solution
A carbon nanotube-polymer composition in powder form with specific density and porosity parameters, allowing for effective redispersion and achieving electrical performance equivalent to solvent-based routes, while minimizing solvent use and transportation volumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon nanotubes are dispersed in solvent-based formulations, then electrical conduction performance is improved, but transportation volume and carbon footprint increase significantly
Solution Approach 1:
The patent changes the physical state parameter of the carbon nanotube formulation from liquid (solvent-based dispersion) to solid (free-flowing powder). This parameter change eliminates the need for large quantities of solvent while maintaining the electrical conduction performance through controlled aggregation states and surface treatments of the nanotubes.
Solution Approach 2:
The patent extracts and removes the solvent component from the carbon nanotube dispersion, transitioning to a solvent-free powder formulation. This extraction eliminates the transportation burden of large solvent volumes while preserving the functional properties of carbon nanotubes through alternative stabilization methods.
2Quantity of substance
If carbon nanotubes are used in dry powder form, then transportation volume is reduced, but electrical conduction performance deteriorates
Solution Approach 1:
The patent employs porous aggregated structures of carbon nanotubes that maintain high surface area and conductive pathways within the powder form. The porous architecture allows for efficient electron transport while keeping the material in a dry, free-flowing state suitable for reduced-volume transportation.
Solution Approach 2:
The patent creates composite structures where carbon nanotubes are combined with conductive matrices or surface-coated with conductive materials. This composite approach ensures that even in dry powder form, the electrical conduction performance is maintained through the synergistic interaction between nanotubes and the conductive matrix.
3Ease of operation
If carbon nanotubes are formulated as granules, then handling is simplified, but redispersion performance and electrical conductivity are insufficient
Solution Approach 1:
The patent segments the carbon nanotube structure into controlled aggregates or clusters rather than using large granules. This segmentation maintains the free-flowing handling characteristics while preserving the nanoscale conductive pathways necessary for high electrical performance, avoiding the aggregation issues that plague granulated forms.
Data Source
Figure 1~2
AI summary
The present invention relates to carbon nanotube compositions that can be implemented in solid form, i.e., in the absence of solvent. These compositions comprise at least one polymer and are readily dispersible in formulations for the manufacture of battery electrodes, and in particular Li-ion batteries, in liquid or solid processes. The invention also relates to the process for obtaining these powders, their use in the manufacture of battery electrodes, and the batteries comprising them.