Conductive-Flake Strengthened Polymer Electrode Film

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Solution Overview

Problem

Existing methods for manufacturing polymer stabilized particle electrodes, particularly through paste-extrusion processes, face challenges in achieving high tensile strength and conductivity while requiring high energy consumption and precise temperature control, which complicates the fabrication and increases costs.

Innovation Solution

The use of conductive flakes in combination with active particles and fibrillatable polymers forms a three-dimensional conductive matrix, enhancing tensile strength and reducing electrical resistance, achieved through a low-energy paste-extrusion process without the need for significant heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If paste-extrusion process is used to manufacture self-supporting electrode films, then resistance to cracking and particle spallation is improved, but tensile strength remains insufficient and manufacturing complexity increases

Engineering Contradiction:

Improveresistance to cracking and particle spallationVSAvoidtensile strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent combines fibrillatable polymer particles with conductive flake particles to create a composite electrode material. The conductive flake particles act as a reinforcing skeleton within the polymer matrix, providing both mechanical strength and electrical conductivity. This composite structure allows the electrode to maintain integrity and resist cracking while achieving sufficient tensile strength for self-supporting applications.

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If conventional electrode films are made with decreasing thickness, then energy density is improved, but manufacturing precision and quality control become increasingly difficult

Engineering Contradiction:

Improveenergy densityVSAvoidhomogeneity of thin film layer

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent changes the fundamental parameters of electrode fabrication by using a dry paste-extrusion process instead of conventional wet coating methods. This allows for precise control of film thickness and composition through extrusion parameters rather than relying on thin film deposition control. The self-supporting nature of the extruded films enables consistent manufacturing across a wide range of thicknesses without compromising homogeneity.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If slurry-coating process is used to produce electrode film, then ease of manufacture is improved, but film structural integrity deteriorates due to rigid porous structure and cracking susceptibility

Engineering Contradiction:

Improveease of electrode film productionVSAvoidfilm structural integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the liquid-based slurry coating mechanism with a dry paste-extrusion mechanism. Instead of applying a liquid slurry that dries to form a rigid porous structure, the process extrudes a cohesive paste that forms a flexible, interconnected network. This mechanical substitution eliminates the drying step and the associated structural weaknesses, while maintaining manufacturing simplicity through continuous extrusion processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 increases tensile strength by 30% to 1600% and reduces electrical resistance by over 70%, simplifying the manufacturing process and reducing energy consumption.

Implementation Method 1

The use of conductive flakes in combination with active particles and fibrillatable polymers forms a three-dimensional conductive matrix, enhancing tensile strength and reducing electrical resistance

Methodology Applied

Scientific EffectConductive matrix formation: Conduction (electrical)

Implementation Method 2

The application of shear to the mixture of the fibrillatable polymer and active particles serves to fibrillate the fibrilatable polymers and forms an interconnecting spider web-like, self-supported film that holds particles together

Methodology Applied

Scientific EffectFibrillation:

Implementation Method 3

The application of shear to the mixture of the fibrillatable polymer and active particles serves to fibrillate the fibrilatable polymers

Methodology Applied

Scientific EffectShear stress: Shear Stress

Data Source

PatentUS11165053B2Conductive-flake strengthened, polymer stabilized electrode composition and method of preparing

Publication Date: 2021.11.02 ADVEN IND INC

AI summary

An electrode film with a high tensile strength and a low electrical resistance is fabricated by using conductive flakes to strengthen polymer stabilized particle electrode. The new compositions and low energy methods are disclosed in this invention. The method includes mixing and blending the particulate materials and fibrilltable polymers with conductive flakes into a paste, fibrillating the polymers, and extruding and rolling the paste into self-supported electrode films.