Multilayer Electrode Films for Energy Density and Power Balance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing energy storage devices, such as lithium-ion batteries, face challenges with charge/discharge rates, energy density, power performance, and durability due to limitations in electrode architecture, particularly in multidimensional designs, which lack precision, durability, and high-speed manufacturing capabilities.
Innovation Solution
The development of multilayer and multidimensional electrode films using actinic and electron beam radiation, combined with EB curable binders and high-aspect ratio additives, allows for improved energy storage devices with enhanced energy and power density, and high-speed manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electrode thickness is increased to provide increased energy density, then energy density is improved, but power density diminishes and durability is compromised
Solution Approach 1:
The electrode is divided into multiple layers with different thicknesses and compositions. The first layer (closer to substrate) has different properties than the second layer (exterior layer), allowing optimization of both energy density and power density across different regions of the electrode structure.
Solution Approach 2:
Different regions of the electrode are assigned different material compositions and structural properties. The first layer contains specific ratios of electrochemically active material, conductive additive, and binder that differ from the second layer, creating local optimization for both energy storage and power delivery.
2Quantity of substance
If electrode thickness is increased to provide increased energy density, then energy density is improved, but durability is compromised at the interface with substrates
Solution Approach 1:
The first layer in contact with the substrate is formulated with specific material compositions that enhance adhesion and mechanical stability at the critical electrode-substrate interface, while the second layer optimizes for energy storage capacity.
Solution Approach 2:
By segmenting the electrode into multiple layers with distinct compositions, the patent isolates the interface region (first layer) with properties optimized for durability and bonding, preventing the compromises that would affect a uniform thick electrode.
3Power
If multidimensional electrode architecture is used to improve performance, then energy and power density are improved, but manufacturing speed decreases significantly
Solution Approach 1:
The multidimensional electrode structure is segmented into multiple layers that can be manufactured sequentially using roll-to-roll processing, enabling high-speed manufacturing while achieving the performance benefits of complex architectures.
Solution Approach 2:
The patent replaces slow transfer molding processes with rapid roll-to-roll coating and curing technologies, substituting mechanical transfer operations with continuous coating and in-line radiation curing to achieve high manufacturing speeds.
4Shape
If transfer molding is used to manufacture 3D electrodes, then complex architectures are achieved, but manufacturing speed is nearly 1000× slower than roll-to-roll processes
Solution Approach 1:
The patent replaces the mechanical transfer molding process with a roll-to-roll coating system combined with actinic and electron beam radiation curing, substituting slow mechanical operations with rapid continuous processing and in-line polymerization.
Solution Approach 2:
The patent utilizes phase transition of the binder material through radiation-induced polymerization, transforming the binder from a liquid or soft state during coating to a cured solid state, enabling rapid in-line manufacturing without slow drying or curing steps.
5Ease of manufacture
If typical polymers and conductive additives are used in thicker planar electrodes, then manufacturing is simplified, but durability is poor
Solution Approach 1:
The patent employs composite material systems where the binder is a polymerizable composition containing multiple functional components that work synergistically to provide both ease of manufacture and superior durability in thick electrode structures.
Solution Approach 2:
The patent changes the chemical and physical parameters of the binder material through radiation-induced polymerization, transforming typical polymers into crosslinked networks with enhanced mechanical strength, chemical stability, and adhesion properties for improved durability.
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
The solution provides energy storage devices with increased energy and power density, durability, and cost-effective manufacturing, surpassing the limitations of traditional planar electrodes.
Implementation Method 1
a polymerizable binder, curable by actinic and electron beam radiation
Implementation Method 2
curable by actinic and electron beam radiation
Data Source
AI summary
The present disclosure describes energy storage (e.g., electrochemical) devices with customized architectures. Such customized architectures include multilayered electrode films and/or multidimensional electrode films.