Interdigitated Electrode Fluid Folding Fabrication
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Solution Overview
Problem
Existing methods struggle to produce tightly spaced interdigitated stripes of dissimilar materials at the micron scale, which is required for advanced energy storage devices like electrodes, as traditional approaches like flow focusing compression are impractical for such fine features.
Innovation Solution
The technique of 'fluid folding' is employed, where two or more flows of dissimilar fluids are combined, split, and recombined in stages to produce interdigitated structures with micron features, using a co-extrusion device that combines and focuses flows to maintain separation and prevent mixing, allowing for the creation of intricate patterns with increased line count and reduced width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If flow focusing compression is used to produce fine features, then material features can be formed at tens of microns scale, but the method becomes impractical for micron scale features with high line count
Solution Approach 1:
The patent segments the single-step flow focusing process into multiple sequential stages. Each stage includes a focusing element that narrows the flow and a splitting element that divides it, creating interdigitated patterns progressively. This multi-stage segmentation enables achievement of micron-scale features with high line count that would be impossible in a single step.
Solution Approach 2:
The patent transitions from planar 2D flow patterns to 3D folded flow structures. By introducing vertical folding dimensions, the system can create complex interdigitated patterns with many lines without requiring proportionally higher flow velocities or pressures, thus maintaining practical manufacturability at micron scales.
2Stability of the object's composition
If multiple materials are dispensed from separate nozzles or multi-material slot containers, then material separation is maintained, but the approach becomes impractical for high line count interdigitated structures
Solution Approach 1:
The patent merges multiple material streams into a single folded flow structure where different materials occupy different spatial regions within the same continuous flow path. This combining approach maintains material separation through controlled folding geometry rather than requiring separate dispensing systems, dramatically reducing device complexity for high line count structures.
Solution Approach 2:
The patent implements nested folding where flow paths are folded back on themselves multiple times, creating a nested structure where earlier flow segments are positioned adjacent to later segments. This nesting enables compact arrangement of many interdigitated lines using a simple single-nozzle or single-slot dispensing system.
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 enables the production of interdigitated structures with micron features on a micron scale, enhancing the performance of energy storage devices by increasing surface area and reducing mixing, thus improving the power output of devices like metal air batteries and fuel cells.
Implementation Method 1
combining and focusing two or more flows, split the combined flow into separate combined flows and then recombine and further focus the flows in repeated stages
Implementation Method 2
The technique of 'fluid folding' is employed, where two or more flows of dissimilar fluids are combined, split, and recombined in stages
Data Source
AI summary
An electrode structure has a layer of at least two interdigitated materials, a first material being an electrically conductive material and a second material being an ionically conductive material, the materials residing co-planarly on a membrane in fluid form, at least one of the interdigitated materials forming a feature having an aspect ratio greater than one. A method of forming an electrode structure includes merging flows of an electrically conductive material and a second material in a first direction into a first combined flow, dividing the first combined flow in a second direction to produce at least two separate flows, each separate flow including flows of the electrically conductive material and the second material, merging the two separate flows into a second combined flow, repeating the merging and dividing flow as desired to produce a final combined flow, and depositing the final combined flow as an interdigitated structure in fluid form onto a substrate such that at least one of the materials forms a feature in the structure having an aspect ratio greater than one.