Interdigitated Finger Coextrusion Device for Micron-Scale Energy Storage
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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 batteries, as traditional approaches are impractical for creating micron-scale features on a micron-scale pitch.
Innovation Solution
A co-extrusion device that combines and focuses two or more flows of dissimilar materials, splits them into separate flows, and then recombines them in a cascading process to produce interdigitated structures with features much smaller and more numerous than the fluidic channels, allowing for the creation of micron-scale interdigitated stripes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multi-material slot containers or separate nozzles are used to dispense materials, then the device structure is simple, but it becomes impractical to create micron-scale features on a micron-scale pitch
Solution Approach 1:
The fluidic channel is divided into multiple separate channels, each carrying a different material. These channels are arranged in parallel and then combined through a series of combining channels that merge the materials in a controlled manner to form the final interdigitated pattern.
Solution Approach 2:
The patent uses three-dimensional fluidic pathways where materials are combined and split in orthogonal directions. The combining channels arrange materials in one dimension while the splitter channels divide them in a perpendicular dimension, enabling precise micron-scale positioning through spatial arrangement rather than single-dimensional control.
2Manufacturing precision
If compression flow focusing is used to produce fine features, then the approach is simple for tens of microns on millimeter scale, but it fails to achieve micron-scale features on micron-scale pitch
Solution Approach 1:
Materials are pre-positioned in separate fluidic channels before the combining stage. The geometry of the combining channels is designed in advance to merge the materials at the correct location and orientation, ensuring that when compression occurs, the materials are already arranged to form the desired interdigitated pattern.
Solution Approach 2:
The combining channels serve as intermediary structures that mediate between the separate material channels and the final interdigitated output. These channels provide a controlled environment where materials can be merged and oriented before the final compression and extrusion, enabling precise feature formation that direct compression cannot achieve alone.
3Stability of the object's composition
If co-laminar flows of two different materials are combined, then the materials remain separate, but the features are too large for advanced energy storage devices
Solution Approach 1:
The combined flow is divided into multiple separate channels, each carrying a different material. These segmented channels are then fed into combining channels that merge the materials in a controlled manner to form the final interdigitated pattern with micron-scale precision.
Solution Approach 2:
The patent transitions from two-dimensional co-laminar flow to three-dimensional fluidic pathways. Materials are combined and split in orthogonal directions, allowing the final interdigitated structure to be formed through spatial arrangement in multiple dimensions rather than relying solely on planar lamination.
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
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 of materials, thus improving the power output of devices like metal air batteries.
Implementation Method 1
flow focusing using compression produces fine features of functional material in paste form
Implementation Method 2
flow focusing using compression produces fine features
Implementation Method 3
combining materials into 'co-laminar' flows, where three laminar flows of two different materials are brought together to form one flow, but where the two materials do not mix together
Data Source
AI summary
A co-extrusion device includes at least one first inlet port to receive a first material, at least one second inlet port to receive a second material, a first combining channel arranged to receive the first material and the second material and combine the first and second materials into a first combined flow flowing in a first direction, a splitter channel arranged to receive the first combined flow and to split the first combined flow into at least two split flows in a second direction at least partially orthogonal to the first direction, wherein each split flow consists of the first and second materials, a second combining channel arranged to receive the split flows and combine the split flows into a second combined flow in the first direction, and at least one exit orifice arranged to allow the materials to exit the device as a single flow.