3D Co-Extruded Battery Electrodes for Power Density
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Solution Overview
Problem
The manufacturing of three-dimensional battery electrode structures with improved performance is hindered by cost inefficiencies, making it challenging to realize their full potential in terms of energy and power density.
Innovation Solution
The use of co-extrusion technology to create interdigitated stripe layers with sacrificial or intermediate materials, which are then filled with electrolyte, allowing for orthogonal layering and reduced transport distances, thereby enhancing energy and power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If three-dimensional battery electrode structures are manufactured using traditional methods, then manufacturing cost increases, but energy and power density improve
Solution Approach 1:
The electrode is segmented into multiple thin layers with interdigitated stripe patterns rather than using a single monolithic structure. This segmentation enables cost-effective manufacturing through layer-by-layer assembly while achieving three-dimensional architecture that improves power density through reduced ion transport distances
Solution Approach 2:
The patent transitions from traditional two-dimensional planar electrodes to three-dimensional stacked layer structures with vertical orientation. This dimensional change enables improved power density by creating multiple current collection pathways and reducing ion transport distances, while the modular layering approach maintains manufacturing efficiency
2Quantity of substance
If material density is increased to achieve higher energy storage, then ion transport speed decreases
Solution Approach 1:
Different regions of the electrode are given different properties: the stripe regions contain high-density active material for energy storage, while the interstitial regions provide electrolyte pathways for fast ion transport. This local differentiation allows simultaneous optimization of both energy capacity and power delivery
Solution Approach 2:
The electrode structure incorporates porous materials with controlled void spaces that allow rapid ion diffusion. The porous architecture provides both high surface area for energy storage and interconnected pathways for fast ion transport, resolving the contradiction between density and transport speed
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 results in increased energy and power density with reduced resistive losses, enabling faster lithium-ion transport and improved battery performance while minimizing the need for inactive layers, thus overcoming the cost inefficiencies in traditional manufacturing methods.
Implementation Method 1
the manufacture of electrodes by co-extruding conductive materials onto a substrate
Implementation Method 2
Less dense material results in more electrolyte filling the volume, which enables faster lithium ion transport in the electrolyte
Data Source
AI summary
A three dimensional electrode structure having a first layer of interdigitated stripes of material oriented in a first direction, and a second layer of interdigitated stripes of material oriented in a second direction residing on the first layer of interdigitated stripes of material. A method of manufacturing a three dimensional electrode structure includes depositing a first layer of interdigitated stripes of an active material and an intermediate material on a substrate in a first direction, and depositing a second layer of interdigitated stripes of the active material and the intermediate material on the first layer in a second direction orthogonal to the first direction.