Laser-Grooved Battery Electrodes for Faster Electrolyte Permeation

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Solution Overview

Problem

The existing methods for manufacturing batteries face challenges in maintaining high energy density while ensuring favorable permeability of the electrolytic solution, often resulting in decreased production efficiency due to increased electrode pressing density.

Innovation Solution

A method of manufacturing a battery that involves forming a groove in the surface of the electrode layer using laser irradiation, which serves as a migration path for the electrolytic solution, thereby promoting its permeation without compromising the energy density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the electrode is pressed at high pressure to increase energy density, then the packing density of electrode active material increases, but the permeability of the electrolytic solution decreases

Engineering Contradiction:

Improveenergy densityVSAvoidpermeability of electrolytic solution

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The invention introduces grooves at specific locations on the electrode surface to create localized regions of high permeability. This allows the electrode to maintain high overall density while having specific channels where electrolyte can efficiently penetrate, resolving the contradiction between high packing density and sufficient permeability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The grooves create a porous-like structure on the electrode surface that facilitates electrolyte penetration. By introducing these controlled voids or channels through grooves, the electrode maintains its dense active material packing while providing pathways for electrolyte to reach the electrode interior efficiently.

Inventive Principle:

Principle #31Porous materials

2Quantity of substance

If the packing density of electrode active material is increased by pressing, then the energy density increases, but the efficiency of liquid injection operation decreases

Engineering Contradiction:

Improveenergy densityVSAvoidliquid injection time

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

By creating grooves at specific locations on the electrode, the invention establishes localized high-permeability regions that serve as preferential pathways for electrolyte injection. This allows rapid electrolyte penetration into the dense electrode structure without requiring reduced overall packing density, thus maintaining high energy density while reducing injection time.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The grooves are formed on the electrode surface before the liquid injection operation, pre-establishing channels that facilitate rapid electrolyte penetration. This preliminary structuring of the electrode surface ensures that when electrolyte injection occurs, the liquid can quickly access the electrode interior through the pre-formed grooves, reducing the overall injection time.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If a separator with a slit is provided between electrodes to reduce liquid injection time, then the permeability improves, but the density equalization of electrodes deteriorates

Engineering Contradiction:

Improveliquid injection efficiencyVSAvoiddensity equalization

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Instead of using a separator with a slit that divides the electrode structure, the invention segments the electrode surface itself by creating grooves. This approach maintains the integrity and density uniformity of the electrode while still providing pathways for electrolyte penetration, avoiding the density equalization problems caused by separator slits.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention creates localized grooves on the electrode surface rather than using a separator with slits. This localized modification provides the necessary permeability pathways without disrupting the overall electrode structure and density distribution, thereby maintaining manufacturing precision while improving liquid injection efficiency.

Inventive Principle:

Principle #3Local quality

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 maintains favorable energy density and permeability of the electrolytic solution, enhancing the overall efficiency of the battery manufacturing process and ensuring uniform density of the electrode layer.

Implementation Method 1

the groove is formed by removing a part of the electrode layer by laser irradiation

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS20250140871A1Method of manufacturing battery, electrode, electrode body, and battery

Publication Date: 2025.05.01 TOYOTA JIDOSHA KK

AI summary

A method of manufacturing a battery that includes an electrode containing a current collector and an electrode layer arranged on the current collector, the method including: a first step of forming an electrode layer on a current collector; and a second step of forming a groove in a surface of the electrode layer, wherein the groove is formed by removing a part of the electrode layer by laser irradiation.