Patterned Electrode Coating for Low-Tortuosity Ion Paths
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Solution Overview
Problem
High electrode density in lithium secondary batteries leads to decreased ion conductivity and increased tortuosity, resulting in a trade-off between battery capacity and output characteristics, necessitating a method to forcibly form a structural ion path to improve conductivity.
Innovation Solution
An apparatus and method for manufacturing electrodes that includes a pattern formation mechanism using ultrasonic vibration to form intaglio pattern grooves in the electrode coating, thereby structurally forming an ion path and improving ion conductivity without altering the physical properties of the electrode collector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electrode density is increased to improve battery capacity, then battery capacity is improved, but ion conductivity decreases and tortuosity increases
Solution Approach 1:
The electrode surface is segmented into multiple regions by forming pattern grooves that divide the coating into distinct segments. This segmentation creates multiple independent ion transport pathways, reducing the overall tortuosity and improving ion conductivity while maintaining high electrode density for high capacity.
Solution Approach 2:
Different regions of the electrode are given different properties through pattern groove formation. The grooved regions have reduced density and increased porosity to facilitate ion transport, while the non-grooved regions maintain high density for high capacity, creating local quality variations that resolve the contradiction.
2Reliability
If laser is used to form patterns that improve ion conductivity, then ion conductivity is improved, but the physical properties of the electrode foil are changed due to high heat
Solution Approach 1:
The thermal field (laser) is replaced with a mechanical field (roller pressing mechanism). Instead of using high-temperature laser to form patterns, a mechanical pressing system with patterned rollers is used to form intaglio grooves through controlled deformation, eliminating the harmful thermal effects while achieving the desired pattern formation.
Solution Approach 2:
Ultrasonic vibration is applied to the pressing mechanism to enhance the pattern formation process. The vibration helps in creating precise intaglio grooves through cyclic mechanical loading, improving the quality of pattern formation while maintaining low temperature and avoiding damage to the electrode foil.
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 approach enhances ion conductivity and reduces tortuosity, enabling high output characteristics in batteries while maintaining electrode stability and preventing physical changes in the electrode collector due to heat.
Implementation Method 1
the pattern formation mechanism uses ultrasonic vibration in a process of forming the pattern groove
Data Source
AI summary
An apparatus for manufacturing an electrode according to an embodiment of the present invention includes a pattern formation mechanism configured to form a pattern groove in an electrode, the electrode including an electrode collector and a coating part made of an electrode active material applied on at least one surface of the electrode collector. The pattern formation mechanism presses a surface of the coating part to form the pattern groove, the pattern groove being an intaglio pattern in the coating part. Related methods for manufacturing the electrode and the electrode manufactured thereby are provided.