Infusion-Mixed Slurry Electrodes for Thicker Battery Layers
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Solution Overview
Problem
Current battery manufacturing methods are complex and costly, leading to batteries with limited thickness, lower capacity, and higher inactive component ratios, which restricts energy density and overall performance.
Innovation Solution
The infusion mixing and manufacturing process involves compressing a dry powder mixture of active and conductive materials and then infusing an electrolyte, allowing for the production of electrodes with increased thickness and reduced inactive components, thereby enhancing energy density and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional coating and drying methods are used to manufacture electrodes, then the manufacturing process is well-established and controllable, but the electrode thickness is limited to less than 100 μm, resulting in lower capacity and energy density
Solution Approach 1:
The patent changes the physical state of the electrode material from a dried solid matrix (traditional method) to a semi-solid slurry state. This is achieved by infusing a solvent into the compacted powder mixture, transforming the material parameters to enable thicker electrode construction without requiring complex multi-step drying and calendaring processes
Solution Approach 2:
The patent extracts and eliminates several complex manufacturing steps including drying, calendaring, and multiple coating operations. By using the slurry infusion method, these separate steps are consolidated into a single infusion process, simplifying the overall manufacturing流程 while enabling greater electrode thickness
2Quantity of substance
If traditional manufacturing methods are used, then the process steps are standardized, but the ratio of inactive components to active materials is high, reducing energy density
Solution Approach 1:
The patent changes the binding mechanism from requiring traditional polymer binders (inactive components) to using solvent-mediated particle bonding. The solvent infuses into the powder mixture and enables particle adhesion through capillary forces and surface tension, eliminating or reducing the need for inactive binder materials
Solution Approach 2:
The solvent acts as an intermediary substance that facilitates particle bonding without becoming a permanent inactive component. It mediates the interaction between active material particles during the infusion process, enabling cohesive electrode structure formation while maintaining high active material content
3Productivity
If electrode thickness is increased beyond traditional limits, then energy density and capacity improve, but manufacturing complexity and equipment requirements increase significantly
Solution Approach 1:
The patent merges multiple manufacturing operations (compaction, solvent infusion, and electrode formation) into a single integrated process step. The infusion apparatus combines the functions of material delivery, solvent injection, and electrode consolidation, enabling thick electrode production without requiring separate complex equipment for each operation
Solution Approach 2:
The slurry-based electrode material is self-forming during the infusion process. The solvent-infused powder mixture automatically consolidates into a cohesive electrode structure through capillary forces and particle packing, eliminating the need for additional calendaring or forming equipment that would otherwise be required
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 process simplifies manufacturing, reduces equipment costs, and results in electrodes with improved conductivity and cycle life, achieving higher energy density and charge capacity compared to traditional methods.
Implementation Method 1
removing air from the porous electrode material with a vacuum source
Implementation Method 2
infusing a liquid electrolyte into the porous electrode material
Data Source
AI summary
Embodiments described in this application relate generally to a system, an apparatus and/or methods for manufacturing electrodes by infusion electrolyte into compacted electrode materials. In some embodiments, a working electrode materials can be produced using an infusion mixing and manufacturing process. In some embodiments, a single-sided finished electrode can be produced directly from a dry powder mixture using an infusion mixing and manufacturing process. In some embodiments, a double-sided finished electrode can be produced directly from a dry powder mixture using an infusion mixing and manufacturing process. The electrodes produced by an infusion mixing and manufacturing process generally perform better than those produced by non-infusion processes.