Electrode-Electrolyte Extrusion for Consistent Polymer Gel Battery Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional methods for manufacturing polymer gel batteries face challenges with increased solid powder loading, leading to higher viscosity and difficulties in achieving consistent and predictable results, especially with extrusion processes compared to slurry casting.
Innovation Solution
A method and apparatus for creating an electrode-electrolyte structure by slurry casting an electrode onto a current collector and then extruding a polymer gel electrolyte onto the electrode, which can be done immediately or after storage, ensuring effective adhesion and contact between the electrolyte and electrode, and allowing for a single continuous process. This involves using a die head to control the extrusion process, minimizing solvent loss, and applying pressure or heat for enhanced adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If extrusion method is used to form polymer gel electrolyte, then manufacturing simplicity is improved, but manufacturing precision deteriorates due to increased viscosity with higher solid powder loading
Solution Approach 1:
The invention divides the manufacturing process into two separate stages: first forming the electrode by slurry casting, then applying the polymer gel electrolyte by extrusion. This segmentation allows each process to be optimized independently - slurry casting ensures precise electrode formation, while extrusion simplifies electrolyte application, thereby resolving the contradiction between manufacturing simplicity and precision.
Solution Approach 2:
The electrode is prepared in advance using slurry casting to ensure precise and consistent formation before the polymer gel electrolyte is extruded onto it. This preliminary action allows the electrode to be optimally prepared with controlled properties, and then the electrolyte can be applied using the simpler extrusion method without compromising overall manufacturing precision.
2Manufacturing precision
If slurry casting is used to form electrode, then manufacturing precision is improved, but productivity deteriorates due to storage requirements
Solution Approach 1:
The invention enables continuous manufacturing by having the polymer gel electrolyte extrusion process immediately follow the slurry casting process without requiring electrode storage. The electrode can be continuously formed and then continuously coated with electrolyte in an uninterrupted workflow, eliminating idle time and storage requirements while maintaining high precision electrode formation.
3Ease of manufacture
If polymer gel electrolyte is extruded onto electrode, then ease of manufacture is improved, but adhesion quality deteriorates
Solution Approach 1:
The electrode is prepared with an optimized surface structure through slurry casting before electrolyte extrusion. This preliminary preparation creates a surface that enhances adhesion, allowing the subsequently extruded polymer gel electrolyte to bond effectively without requiring complex application processes, thus maintaining both ease of manufacture and adhesion quality.
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 method enables quick and simple assembly of electrode-electrolyte structures with improved adhesion and contact, enhancing cell performance by filling surface pores of the electrode and allowing for precise control of the electrolyte deposition, thus overcoming the limitations of traditional extrusion methods.
Implementation Method 1
the method may comprise extruding the polymer gel electrolyte onto the electrode surface such that the polymer gel electrolyte at least partially fills the surface pores
Implementation Method 2
the method may comprise applying pressure to the polymer gel electrolyte during or after extrusion, the applied pressure having a component that is substantially perpendicular to an electrode-electrolyte interface
Implementation Method 3
the method may comprise heating the polymer gel electrolyte during and/or after extrusion
Data Source
AI summary
Apparatus for making an electrode-electrolyte structure includes: a die head defining a substrate pathway for passage of an electrode substrate through the die head from a substrate inlet to a substrate outlet, and an electrolyte pathway for passage of an electrolyte gel through the die head; an electrode feeder for feeding an electrode substrate along the substrate pathway; and an electrolyte feeder for feeding a polymer gel electrolyte along the electrolyte pathway. The electrolyte pathway is arranged to meet the substrate pathway at a junction arranged between the substrate inlet and the substrate outlet, to extrude the electrolyte onto the electrode substrate as it is fed along the substrate pathway.