Dry Powder Electrode Roll Forming Without Solvent Drying
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Solution Overview
Problem
Conventional methods for manufacturing electrodes for energy storage devices, such as Li-ion and all solid-state batteries, are energy-intensive, rely on hazardous solvents, and face scalability challenges, particularly in forming thin film solid-state electrolytes and composite electrodes.
Innovation Solution
A dry manufacturing system and method using a substrate with a powder applicator, spreading rollers, and compaction rollers to deposit and form electrodes without solvents, ensuring uniformity and scalability by employing nano-particle coated micro-particles for improved flowability and cohesion reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional slurry casting techniques are used for electrode manufacturing, then electrode formation is achieved, but energy consumption and greenhouse gas emissions increase significantly
Solution Approach 1:
The patent extracts and eliminates the solvent component from the conventional slurry casting process, transitioning to a dry powder formulation. This removal of the harmful solvent medium enables electrode manufacturing without the energy-intensive drying step, directly resolving the contradiction between ease of manufacture and energy consumption
Solution Approach 2:
The patent changes the physical state parameter of the electrode formulation from a liquid slurry to a dry powder form. This parameter change fundamentally alters the manufacturing process, eliminating the need for solvent evaporation and associated energy consumption while maintaining electrode formation capability
2Ease of manufacture
If conventional slurry casting techniques are used for electrode manufacturing, then electrode formation is achieved, but environmentally hazardous solvents are required
Solution Approach 1:
The patent extracts and eliminates the solvent component from the conventional slurry casting process, transitioning to a dry powder formulation. This removal of the harmful solvent medium enables electrode manufacturing without environmental hazards associated with solvent exposure and disposal
Solution Approach 2:
The patent converts the previously harmful solvent requirement into a benefit by demonstrating that solvent-free dry powder formulation can achieve superior electrode uniformity and performance, particularly for solid-state battery applications where solvent compatibility is critical
3Object-affected harmful factors
If dry mixing-based palletization processes are used for solid-state batteries, then solvent compatibility issues are circumvented, but scalability challenges arise
Solution Approach 1:
The patent replaces the mechanical pressing process with a controlled powder deposition and consolidation system. This substitution enables precise control over electrode thickness and uniformity while maintaining scalability, overcoming the limitations of traditional dry mixing and pressing methods
Solution Approach 2:
The patent changes the processing parameters from bulk dry mixing and pressing to controlled layer-by-layer powder deposition followed by localized consolidation. This parameter change enables precise control over electrode properties while maintaining manufacturing scalability for solid-state batteries
4Productivity
If conventional slurry casting techniques are used for electrode manufacturing, then electrode production is achieved, but equipment footprint and manufacturing costs increase
Solution Approach 1:
The patent extracts and eliminates the drying oven and solvent recovery systems from the conventional slurry casting equipment. This removal of bulky equipment significantly reduces the manufacturing footprint while maintaining continuous electrode production capability
Solution Approach 2:
The patent implements a continuous dry powder deposition and consolidation process that eliminates the batch processing nature of conventional methods. This continuous operation maintains high productivity while reducing equipment complexity and footprint through streamlined processing
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
Reduces energy consumption and greenhouse gas emissions by up to 40% compared to conventional methods, enabling large-scale production with reduced equipment footprint and costs, while maintaining electrode uniformity and compatibility with solid-state electrolytes.
Implementation Method 1
a powder applicator configured to deposit a dry powder onto a surface of the substrate
Implementation Method 2
The radially outer surface of the upper spreading roller is configured to directly contact and spread the dry powder on the substrate
Implementation Method 3
The radially outer surface of the upper compaction roller is configured to directly contact and compress the dry powder to form the electrode on the surface of the substrate
Data Source
AI summary
A system for dry manufacturing an electrode for an energy storage device includes a substrate configured to move in a feed direction. In addition, the system includes a powder applicator configured to deposit a dry powder onto a surface of the substrate. Further, the system includes at least one pair of spreading rollers. The pair of spreading rollers includes an upper spreading roller and a lower spreading roller positioned below the upper spreading roller. The upper spreading roller and the lower spreading roller are positioned downstream of the powder applicator relative to the feed direction. Each spreading roller has a central axis of rotation and a radially outer surface. The radially outer surface of the upper spreading roller is configured to directly contact and spread the dry powder on the substrate. The upper spreading roller is configured to rotate in a rotational direction that is counter to the feed direction of the substrate proximal the substrate and dry powder and the lower spreading roller is configured to rotate in a rotational direction that is the same as the rotational direction of the upper spreading roller. Still further, the system includes at least one pair of compaction rollers. The pair of compaction rollers includes an upper compaction roller and a lower compaction roller positioned below the upper compaction roller. The at least one pair of spreading rollers are positioned downstream of the upper spreading roller and the lower spreading roller relative to the feed direction. Each compaction roller has a central axis of rotation and a radially outer surface. The radially outer surface of the upper compaction roller is configured to directly contact and compress the dry powder to form the electrode on the surface of the substrate. The upper compaction roller is configured to rotate in a rotational direction that is opposite to the rotational direction of the upper spreading roller.