Material Layer Patterning With Dense Particle Filling for 3D Batteries
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Solution Overview
Problem
Existing additive manufacturing methods for forming material layers in all-solid-state batteries result in reduced density due to the inclusion of binder resins and solvents in inks, leading to inefficient material distribution.
Innovation Solution
A method involving the arrangement of first particles in a pattern on a base material, followed by the dense placement of second particles in non-arranged regions using bearing materials that rub against the base material, enhancing material density through adhesive forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ink jet method is used to apply multiple inks for forming material layers, then various materials can be arranged in predetermined patterns, but the density of each material in the resulting material layer is reduced due to inclusion of binder resins, solvents, and dispersing agents
Solution Approach 1:
The invention extracts and removes the harmful components (binder resins, solvents, dispersing agents) from the ink formulation, retaining only the essential functional materials (active materials, conductive materials). This extraction eliminates the volume occupied by non-functional components, thereby increasing material density while preserving the ability to form precise patterns through controlled application of the concentrated ink composition
Solution Approach 2:
The invention changes the concentration parameter of the ink composition by formulating it with high solid content and low solvent content. This parameter change transforms the ink from a dilute suspension to a concentrated material delivery vehicle, enabling high-density material layers to be formed while maintaining pattern formation capability through controlled deposition
2Adaptability or versatility
If multiple inks containing binder resins and solvents are used, then various functional materials can be applied, but the material distribution efficiency is reduced
Solution Approach 1:
The invention extracts and eliminates the non-functional components (binder resins, solvents, dispersing agents) that hinder material distribution efficiency. By removing these extraneous substances, the ink becomes a direct carrier of functional materials, enabling efficient material distribution while still supporting multiple material types through separate ink formulations
Solution Approach 2:
The invention segments the ink formulation into distinct functional material components without requiring binding agents or solvents to hold them together. Each functional material (active material, conductive material) can be independently formulated and applied, improving distribution efficiency while maintaining versatility through modular ink design
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 enables the formation of material layers with high material density and precise patterning, improving the efficiency and performance of all-solid-state batteries by ensuring optimal distribution of active materials.
Implementation Method 1
a step of rubbing bearing materials that carry the second particles against the base material on which the first particles are arranged
Implementation Method 2
enhancing material density through adhesive forces
Data Source
AI summary
A method for manufacturing a material layer includes a first step S101 of arranging first particles P1 in a pattern on a base material 11 and a second step S102 of arranging second particles in regions in which the first particles P1 are not arranged on the base material 11. The second step S102 includes a step of rubbing bearing materials S2 that carry the second particles P2 against the base material 11 on which the first particles P1 are arranged.