Hybrid Multilayer Electrode Films for Power and Capacity Gains
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Solution Overview
Problem
Existing methods of electrode film fabrication for energy storage devices impose practical limits on structural electrode properties, limiting the performance of energy storage devices such as batteries and capacitors.
Innovation Solution
A multilayer hybrid electrode film is developed, comprising a dry-processed active layer with a fibrillizable binder and a wet-processed active layer with processing solvent residue, which are laminated together with optional additional layers like composite powders or adhesive pastes, to create a free-standing film suitable for energy storage devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing single-layer electrode film fabrication methods are used, then manufacturing simplicity is maintained, but electrode structural properties and device performance are limited
Solution Approach 1:
The electrode film is divided into multiple functional layers (collecting current layer and active material layer) with distinct compositions and properties. The collecting current layer contains conductive polymer and binder, while the active material layer contains electroactive polymer and binder, allowing each layer to be optimized independently for its specific function while achieving superior overall device performance
Solution Approach 2:
The invention uses composite material structures where the collecting current layer and active material layer are laminated together. Each layer is composed of multiple components (polymers, binders, active materials) with specific ratios, creating a composite electrode structure that combines the advantages of different materials to enhance both reliability and energy storage capacity
2Quantity of substance
If conventional electrode fabrication methods are used, then manufacturing simplicity is maintained, but energy storage capacity and operating power are limited
Solution Approach 1:
The electrode is segmented into functional layers that can be fabricated separately using conventional techniques and then laminated together. This allows optimization of each layer's composition for maximum energy storage capacity while using existing manufacturing methods, thereby increasing quantity of active material without significantly increasing manufacturing complexity
Solution Approach 2:
Composite electrode structures with optimized material ratios and layer configurations enable higher energy storage capacity by maximizing the content of electroactive materials while maintaining manufacturability through lamination of pre-fabricated layers
3Stability of the object's composition
If single-layer electrode films are used, then structural simplicity is maintained, but pore structure and stability are insufficient
Solution Approach 1:
Dividing the electrode into collecting current layer and active material layer allows each layer to be optimized for its specific function, improving overall structural stability and compositional consistency while maintaining reasonable complexity through functional specialization
Solution Approach 2:
The composite laminated structure provides enhanced stability through the synergistic combination of layers with different compositions and properties, creating a more robust electrode structure that maintains compositional integrity during operation
4Power
If existing fabrication methods are used, then manufacturing simplicity is maintained, but equivalent series resistance and capacity fade are reduced
Solution Approach 1:
The segmented electrode structure with dedicated collecting current layer containing conductive polymer enhances electrical conductivity and reduces equivalent series resistance, improving power delivery capability while maintaining manageable structural complexity through functional layering
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 multilayer electrode film enhances the operating power and energy storage capacity of devices, offering improved pore structure, cost-effectiveness, and stability, with reduced equivalent series resistance and capacity fade over the device's life.
Implementation Method 1
the dry processed active layer comprises an first active material and a first binder. In some embodiments, the first binder is a first fibrillizable binder.
Implementation Method 2
a wet-processed active layer including a second active material, and at least some processing solvent residue
Implementation Method 3
The multilayer electrode film includes a dry-processed active layer including a first active material, and a fibrillized binder, wherein the dry processed active layer is absent of processing solvent residue, and a wet-processed active layer including a second active material, and at least some processing solvent residue
Data Source
AI summary
Provided herein are energy storage device electrode films comprising a hybrid electrode film, and methods of forming such multilayer hybrid electrode films and energy storage devices comprising multilayer hybrid electrode films. Each hybrid electrode film may comprise a self-supporting dry coated active layer and a wet cast active layer, wherein each active layer comprises a binder and an active material. The binder and/or active material may be the same or different as any other active layer. The hybrid multilayer electrode film may further comprise at least one additional layer, and the hybrid multilayer electrode film may be laminated with a current collector to form an electrode.