Co-extrusion Print Head for Conformal Battery Separator
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Solution Overview
Problem
Existing battery manufacturing methods using co-extrusion apparatuses fail to form electrodes and separators simultaneously, resulting in non-conformal separators that can lead to shorting due to mismatched dimensions and alignment issues.
Innovation Solution
A co-extrusion print head design with specific inlet and merge portions, and nozzle configurations that allow for simultaneous extrusion of electrode and separator materials, enabling the formation of a conformal separator structure around the electrodes, which covers the top and sides, ensuring proper alignment and preventing shorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrodes and separators are manufactured separately and then assembled, then manufacturing flexibility is maintained, but alignment precision deteriorates leading to non-conformal separators and potential shorting
Solution Approach 1:
The patent combines the electrode and separator manufacturing processes into a single co-extrusion operation. The print head simultaneously extrudes both materials in their respective layers, ensuring they are deposited with precise alignment from the start. This merging of operations eliminates the alignment issues that arise from separate manufacturing and assembly steps.
Solution Approach 2:
The patent implements preliminary action by forming the separator conformally around the electrode during the same deposition process. The separator material is extruded in a manner that pre-establishes the conformal relationship with the electrode, rather than attempting to achieve alignment during subsequent assembly operations.
2Reliability
If oversized separator sheets are used to prevent edge contact, then safety is improved, but material efficiency deteriorates due to waste
Solution Approach 1:
The patent applies local quality by creating a separator with non-uniform dimensions that are optimized for different locations. The separator is extruded to be wider than the electrode at the edges to prevent shorting, but precisely matches the electrode width in the central region, eliminating the need for uniformly oversized separators and reducing material waste.
Solution Approach 2:
The patent uses fluid dynamics control in the co-extrusion process to precisely shape the separator material as it is deposited. By controlling the flow and distribution of the separator slurry through the print head nozzles, the system achieves precise dimensional control and conformal deposition without requiring excess material.
3Productivity
If sequential layer deposition is used to form thin-film batteries, then manufacturing simplicity is maintained, but production efficiency deteriorates due to multiple steps
Solution Approach 1:
The patent merges multiple deposition operations into a single co-extrusion process. Instead of sequentially depositing electrode and separator layers in separate steps, the system simultaneously extrudes both materials in their respective layers during one continuous operation, doubling production efficiency while maintaining process simplicity.
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 conformal separator structure reduces the risk of shorting in battery cells, eliminating the need for oversized separator sheets and minimizing edge contact between electrodes, thereby enhancing battery safety and manufacturing efficiency.
Implementation Method 1
a co-extrusion apparatus, which has a print head with a plurality of channels and nozzles
Implementation Method 2
arranged to receive a separator material from a separator inlet port and arranged to receive an electrode material from an electrode inlet port
Data Source
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AI summary
A co-extrusion print head has at least one separator inlet port (64), at least a first, second and third series of channels arranged to receive a separator material from the separator inlet port (64), at least one electrode inlet port (68), a fourth series of channels arranged to receive an electrode material from the electrode inlet port (68), a first merge portion (85, 87) connected to the first, second, third and fourth series of channels, the merge portion positioned to receive and merge the separator material into a separator flow and the electrode material into an electrode flow, a second merge portion (89) connected to the first merge portion (85, 87), the second merge portion (89) positioned to receive and merge the separator flows and the electrode flows, and an outlet port (91) connected to the second merge portion (89), the outlet port (91) arranged to deposit the separator and electrode materials from the merge portion as a stack on a substrate.