Patterned Thick Battery Electrodes for Better Rate Performance
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Solution Overview
Problem
Existing methods for manufacturing battery cell electrodes do not effectively pattern active material layers, leading to suboptimal electrochemical performance, particularly in thicker electrodes, which limits their energy density and rate performance.
Innovation Solution
A method involving extrusion of an electrode mixture through an extruder to form an active material layer, followed by patterning with a patterned roller to create features in the layer, which can be laminated to a current collector before or after patterning, enhancing surface area and electrolyte contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing manufacturing methods are used for electrodes, then the manufacturing process is simple, but the electrochemical performance of thick electrodes is suboptimal with limited energy density and rate performance
Solution Approach 1:
The active material layer is segmented into multiple discrete features or islands separated by voids, rather than forming a continuous layer. This segmentation increases the effective surface area and improves electrolyte access to active material throughout the thick electrode, enhancing electrochemical performance and rate capability
Solution Approach 2:
The invention transitions from a two-dimensional continuous layer to a three-dimensional patterned structure with vertical features extending through the thickness of the electrode. This dimensional change creates pathways for electrolyte penetration and increases the active surface area available for electrochemical reactions
2Quantity of substance
If the active material layer is made thicker to increase energy density, then the energy density improves, but the rate performance and electrochemical performance deteriorate due to limited electrolyte access
Solution Approach 1:
By segmenting the thick active material layer into discrete features separated by voids, the invention maintains high energy density through increased active material quantity while simultaneously improving rate performance by enabling electrolyte access to all regions of the electrode
Solution Approach 2:
The patterned structure creates a porous architecture with voids between features that facilitate electrolyte penetration deep into the thick electrode, ensuring that rate performance is not compromised by increased thickness
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 patterning process improves the electrochemical performance of thick electrodes by increasing surface area and kinetics, resulting in higher energy density and rate performance.
Implementation Method 1
patterning the active material layer using a patterned roller including a plurality of projections that form a plurality of features extending into the active material layer
Implementation Method 2
extruding a mixture including an active material, a conductive additive, a binder, and a solvent from an extruder to form an active material layer
Implementation Method 3
laminating the active material layer and a current collector
Data Source
AI summary
A method for manufacturing patterned electrodes includes extruding a mixture including an active material, a conductive additive, a binder, and a solvent from an extruder to form an active material layer; laminating the active material layer and a current collector; and patterning the active material layer using a patterned roller including a plurality of projections that form a plurality of features extending into the active material layer.