Co-Extruded Lithium Polymer Layers for 3D-Printed Battery Electrodes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D-printed batteries face challenges such as nozzle clogging, particle aggregation, insufficient printer resolution, large electrode thickness, and rough surface finish, limiting their performance compared to conventional batteries.
Innovation Solution
A composition-of-matter comprising multiple thermoplastic polymer layers, including a first layer capable of reversibly releasing lithium, a second layer conducting lithium ions, and a third layer capable of reversibly releasing lithium, which are co-extruded to form lithium-based electrodes and a solid electrolyte, facilitating efficient ion transfer and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional doctor-blade casting technique is used to fabricate electrodes, then manufacturing precision and surface finish are improved, but device complexity and manufacturing process complexity increase
Solution Approach 1:
The patent combines multiple manufacturing operations into a single 3D printing process. The extrusion-based 3D printing system fabricates electrodes, separators, and assembly structures in one continuous operation, eliminating the need for separate doctor-blade casting, drying, and assembly steps. This merging of processes maintains manufacturing precision while reducing overall process complexity.
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from planar doctor-blade casting to three-dimensional extrusion printing. This parameter change enables direct fabrication of complex 3D electrode architectures with controlled surface finish, eliminating the need for conventional multi-step processing while achieving comparable or superior precision.
2Adaptability or versatility
If 3D printing is used to fabricate batteries, then device flexibility and design freedom are improved, but manufacturing precision and surface finish deteriorate
Solution Approach 1:
The patent applies local quality by optimizing specific regions of the printed electrode. The extrusion process enables variation in material composition, porosity, and density at different locations within the electrode structure. This allows high-precision surfaces in critical areas while maintaining design freedom in non-critical regions, resolving the contradiction between flexibility and precision.
Solution Approach 2:
The patent incorporates preliminary action by pre-programming the extrusion parameters and toolpath planning before manufacturing. This allows optimization of surface finish in advance for specific regions, ensuring high precision where needed while maintaining overall design flexibility. The preliminary configuration of printing parameters enables post-manufacturing precision without sacrificing adaptability.
3Quantity of substance
If larger electrode thickness is used in 3D-printed batteries, then energy density is improved, but diffusion path length and ohmic losses increase
Solution Approach 1:
The patent transitions from two-dimensional planar electrodes to three-dimensional printed structures. This dimensional change enables electrodes to extend in multiple spatial directions, increasing the quantity of active material while maintaining short diffusion paths through the third dimension. The 3D architecture allows material to be distributed throughout volume rather than confined to planar surfaces, achieving high energy density without increased ohmic losses.
Solution Approach 2:
The patent segments the electrode into multiple printed layers or regions with optimized thicknesses. Instead of using a single thick electrode that increases resistance, the structure is divided into thinner functional segments that maintain short diffusion paths. This segmentation allows increased total material quantity through stacked layers while keeping individual diffusion distances short, reducing ohmic losses.
4Reliability
If particles are used in printing media for battery fabrication, then electrochemical performance is improved, but nozzle clogging and particle aggregation occur
Solution Approach 1:
The patent changes the physical parameters of the printing media by using thermoplastic polymer compositions with controlled viscosity and melting characteristics. These parameter changes allow particles to be suspended or dissolved in a matrix that flows smoothly through the nozzle when molten, preventing clogging. After extrusion and cooling, the particles are released and aggregated into the desired electrochemical structure, maintaining performance while eliminating nozzle blockage.
Solution Approach 2:
The patent introduces a thermoplastic polymer as an intermediary medium that carries the electrochemical particles through the printing process. This intermediary material prevents direct particle-to-nozzle contact that causes clogging, while still enabling particle deposition and aggregation in the final structure. The polymer matrix acts as a protective carrier that releases particles in a controlled manner after extrusion.
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 solution enables the simple manufacture of lithium ion-based electrochemical systems with enhanced interfacial areas, reducing tortuosity and resistance, thereby improving efficiency and energy density, and allows for the production of flexible, bendable electrochemical devices.
Implementation Method 1
dispensing, in a configured pattern corresponding to the shape of the electrode, a model composition which comprises a substance capable of reversibly releasing an electrochemically-active agent... wherein dispensing comprises heating a filament comprising the model composition and dispensing a heated composition
Implementation Method 2
a first layer which comprises a first thermoplastic polymer and a substance capable of reversibly releasing lithium or a delithiated form of the substance
Implementation Method 3
a second layer comprising a second thermoplastic polymer and being capable of conducting lithium ions
Data Source
AI summary
A composition-of-matter is described herein, comprising a first layer and third layer separated by a second layer. The first and third layers each comprise a thermoplastic polymer and a substance capable of reversibly releasing lithium or a delithiated form of the substance. The second layer comprises a thermoplastic polymer and is capable of conducting lithium ions. Further described herein is an electrochemical system comprising the composition-of-matter, wherein the first and third layers are each a lithium-based electrode, and batteries and supercapacitors comprising such an electrochemical system, as well as methods for preparing the composition-of-matter or the electrochemical system.