Patterned Multilayered Electrodes for Battery Adhesion
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Solution Overview
Problem
Current battery technologies rely on expensive and environmentally harmful solvents in manufacturing processes for electrodes, and there is a need for improved energy storage solutions that enhance electrochemical performance and reduce environmental impact.
Innovation Solution
The development of patterned multilayered electrodes with a current collector, a first active material layer, and a second active material layer featuring cavities and protrusions, along with an integrated ceramic separator, which improves adhesion, ion mobility, and mechanical robustness, while reducing interfacial resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional solvents are used in electrode manufacturing, then manufacturing process is established, but environmental harm and cost increase
Solution Approach 1:
The patent removes harmful solvents from the electrode manufacturing process entirely, replacing them with solvent-free slurry coatings and water-based binders. This extraction of harmful substances eliminates environmental damage while maintaining manufacturing capability through alternative processing methods.
Solution Approach 2:
The patent changes the chemical composition parameters of the manufacturing process by substituting conventional organic solvents with water-based solutions and solvent-free materials. This parameter change transforms the manufacturing process from harmful to environmentally friendly while preserving production efficiency.
2Ease of manufacture
If flat electrode structure is used, then manufacturing is simple, but adhesion between layers and ion mobility are insufficient
Solution Approach 1:
The patent segments the electrode into multiple functional layers with distinct purposes: current collector, active material layer, adhesive layer, and protective layer. This segmentation allows each layer to optimize its specific function, improving overall adhesion and ion mobility while maintaining manufacturing feasibility through standardized layering processes.
Solution Approach 2:
The patent transitions from a two-dimensional flat electrode structure to a three-dimensional multilayered architecture with vertical stacking. This dimensional change creates additional interfaces and pathways for ion transport and adhesion, significantly enhancing performance while the layered structure remains manufacturable through sequential deposition.
3Strength
If material expansion is not accommodated, then structure remains compact, but electrochemical performance deteriorates
Solution Approach 1:
The patent incorporates expansion accommodation features in advance during electrode design, such as flexible adhesive layers and porous structures that can absorb volume changes. This beforehand cushioning prevents structural damage during charge-discharge cycles while maintaining compact form factor, thereby preserving both structural integrity and electrochemical performance.
Data Source
AI summary
A patterned multilayered electrode includes at least one electrode layer comprising an array of cavities, and at least one electrode layer comprising a plurality of protrusions interlocked with the array of cavities. In some examples, a patterned multilayered electrode includes a first active material layer, a second active material layer comprising an array of cavities, and a separator layer comprising a plurality of protrusions interlocked with the cavities of the second active material layer. In some examples, a patterned multilayered electrode includes a first active material layer comprising an array of cavities and a second active material layer comprising a plurality of protrusions interlocked with the cavities of the first active material layer.