Flexible Packaging Embedded Electrode Eliminates Current Collectors
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Solution Overview
Problem
Conventional battery designs face challenges in achieving high energy density, mechanical flexibility, and sustainability due to the inclusion of non-active components like metal-based current collectors, binders, and packaging materials, which hinder the development of thin, flexible, and wearable batteries that can withstand various mechanical stresses.
Innovation Solution
A method for producing self-standing electrodes by aerosolizing electrode active materials and blending them with carbon nanotubes in a carrier gas, then depositing the mixture on polymer particles and heating near the polymer's melting point to form a flexible composite, eliminating the need for metal-based current collectors and binders, and utilizing polymer-based packaging materials for enhanced flexibility and energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If metal-based current collectors and binders are used in battery electrodes, then structural integrity and electrical conductivity are improved, but energy density and mechanical flexibility deteriorate due to the weight and rigidity of these non-active components
Solution Approach 1:
The invention extracts and removes metal-based current collectors and traditional binders from the electrode structure, replacing them with a self-standing electrode material composed of active material particles, conductive additive, and binder in a specific weight ratio range (70:5:25 to 85:10:5). This extraction eliminates the harmful effects of heavy, rigid metal components while maintaining structural integrity through the optimized composite formulation.
Solution Approach 2:
The invention creates a composite electrode material consisting of active material particles, conductive additive, and binder in carefully controlled weight ratios. This composite structure provides both mechanical flexibility and structural integrity without requiring separate metal current collector layers, thereby improving energy density while maintaining necessary mechanical properties.
2Stability of the object's composition
If traditional liquid mixing processes are used to prepare electrode materials, then homogeneity of mixing is improved, but nanotube properties deteriorate due to degradation from ball milling, sonication, and other harsh mixing techniques
Solution Approach 1:
The invention replaces harsh mechanical mixing methods (ball milling, sonication) with a gentler mixing approach that preserves nanotube aspect ratio and prevents defect formation. The optimized mixing process achieves homogeneous distribution of conductive additives and active material particles without degrading the nanotube structure, maintaining both nanotube properties and mixing uniformity.
3Reliability
If carbon nanotubes are used to enhance electrode performance, then electrical conductivity and mechanical strength are improved, but manufacturing complexity and cost increase due to expensive liquid processing steps
Solution Approach 1:
The invention optimizes the weight ratio parameters of conductive additive, binder, and active material to achieve high electrical conductivity and mechanical strength without requiring complex liquid processing steps. By controlling the composition within specific ranges (conductive additive: 5-20 wt%, binder: 25-40 wt%), the invention simplifies manufacturing while maintaining reliable electrical 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 approach results in flexible, high-energy-density batteries that are free from metal-based current collectors and binders, maintaining mechanical integrity and flexibility, suitable for wearable devices and applications requiring thin, flexible, and durable power sources.
Implementation Method 1
aerosolizing an electrode active material to produce an aerosolized electrode active material powder; blending the aerosolized electrode active material powder with carbon nanotubes in a carrier gas
Implementation Method 2
depositing the mixture on a surface of polymer particles or another suitable form of polymer
Implementation Method 3
heating the mixture and the polymer to a temperature near the melting point of the polymer
Implementation Method 4
heating the mixture and the polymer to a temperature near the melting point of the polymer
Data Source
AI summary
The present disclosure relates to a method of making carbon nanotube supported self-standing electrodes embedded in a polymer based battery packaging material. The present disclosure further relates to a method of continuously making carbon nanotube supported self-standing electrodes embedded in a polymer based battery packaging material. The resulting self-standing electrodes may be used in a wearable and flexible battery.