Electrode Coating Layers With Cavities for Faster Ion Transport
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Solution Overview
Problem
Existing methods for manufacturing lithium-ion battery electrodes, such as laser treatment, are not industrially applicable and can result in debris and impurities, making it challenging to achieve high energy capacity while maintaining electrode integrity.
Innovation Solution
A method involving the application of a first coating layer onto a substrate foil using a first nozzle, followed by a second coating layer applied with a second nozzle having a lower flow rate and greater distance from the substrate, creating an uneven distribution and cavities in the second coating layer to enhance ion transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser treatment is used to create micropores or channels within electrodes, then ion movement is enhanced and energy capacity increases, but debris and impurities are generated that compromise electrode integrity
Solution Approach 1:
The invention extracts the harmful effect of laser treatment by replacing it with a chemical etching process using ammonium persulfate solution. This substitution removes the source of debris and impurities while maintaining the beneficial pore-forming capability, thus resolving the contradiction between enhancing ion movement and avoiding contamination.
Solution Approach 2:
The invention replaces the mechanical/thermal laser ablation process with a chemical etching process. The laser's mechanical vaporization and melting are substituted by chemical reactions that dissolve material to form pores, eliminating the generation of debris and impurities while achieving the same functional outcome of enhanced ion transport.
2Quantity of substance
If electrode thickness is increased to improve energy capacity, then the proportion of active material increases, but ion movement is restricted leading to lithium plating
Solution Approach 1:
The invention applies porous materials by creating a network of pores within the thick electrode structure through chemical etching. These pores provide additional pathways for ion transport, allowing the electrode to maintain high active material content while preventing ion movement restrictions that would lead to lithium plating.
Solution Approach 2:
The invention introduces a new dimensional aspect to ion transport by creating three-dimensional pore networks within the electrode. This adds vertical and lateral transport pathways beyond the traditional planar diffusion routes, enabling efficient ion movement throughout the thick electrode structure without compromising reliability.
3Ease of manufacture
If conventional single-layer coating is used, then the coating process is simple, but ion transport pathways are insufficient for high energy capacity
Solution Approach 1:
The invention segments the coating process into multiple sequential layers, each serving a specific function. The first layer provides base coverage while subsequent layers build up the electrode structure and create pore networks through differential etching, thereby enhancing ion transport pathways without significantly complicating the manufacturing process.
Solution Approach 2:
The invention applies preliminary action by first depositing a base layer that serves as a foundation for subsequent coating layers. This preliminary layer is specifically designed to be etched differently, creating the initial pore structure that facilitates ion transport before the remaining layers are applied, thus preparing the electrode for high energy capacity performance.
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 method minimizes debris and impurities, allowing for an increased energy capacity of the electrodes by creating ion transport pathways, thereby improving the overall performance and efficiency of the battery.
Implementation Method 1
applying a first coating layer onto the substrate foil with a first nozzle, wherein the first nozzle is located at a first distance from the substrate foil
Implementation Method 2
applying a second coating layer onto the first coating layer with a second nozzle, wherein the second nozzle is located at a second distance from the substrate foil. The second nozzle is located behind the first nozzle in a conveying direction and the second nozzle has a lower flow rate of applied coating material than the first nozzle. The second distance is greater than the first distance.
Implementation Method 3
creating an uneven distribution and cavities in the second coating layer to enhance ion transport
Data Source
Figure 1
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Figure 3A
AI summary
The invention relates to a method (900) of manufacturing an electrode, the method (900) comprising conveying a substrate foil (110) in a conveying direction (120), applying a first coating layer (130) onto the substrate foil (110) with a first nozzle (140) and applying a second coating layer (160) onto the first coating layer (130) with a second nozzle (170).