Plasma Spray Deposition of Lithium-Ion Battery Nanocrystals
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Solution Overview
Problem
There is a need for thinner, lighter, and more cost-effective manufacturing of lithium-ion batteries, particularly in the context of thin-film Li-ion batteries used in various applications, where current methods do not efficiently achieve these goals.
Innovation Solution
The method involves forming an electrochemical film on a substrate using a processing chamber with an activation chamber, where energy is applied to electrochemical precursors to create nanocrystals, which are then deposited on the substrate, often with the assistance of a polymer binder to enhance adhesion and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional paste application and hot rolling methods are used, then battery capacity and energy density are achieved, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The patent replaces conventional mechanical paste application and hot rolling processes with plasma spraying technology. The plasma spray apparatus uses a plasma jet to deposit active material directly onto current collectors in a controlled manner, eliminating the need for paste mixing, application, and thermal processing equipment, thereby reducing manufacturing complexity and cost while improving production efficiency
Solution Approach 2:
The invention changes the physical state and deposition parameters of active materials by using plasma spraying. Instead of applying paste that requires drying and sintering, the process deposits materials in a plasma state that directly forms functional layers upon contact with the substrate, fundamentally changing the manufacturing parameters and reducing process steps
2Weight of moving object
If thicker current collectors and electrode layers are used, then mechanical strength and structural stability are maintained, but battery weight increases and energy density decreases
Solution Approach 1:
The patent employs thin-film deposition techniques where active materials are sprayed as fine particles or plasma that form thin, uniform layers on current collectors. This approach enables the use of thinner electrode structures that reduce overall battery weight while maintaining structural integrity through controlled deposition and material selection
Solution Approach 2:
The invention uses composite material structures where active materials are deposited in combination with conductive additives and binders in controlled ratios. The plasma spraying process enables precise control of material composition and distribution, creating optimized composite structures that provide both mechanical strength and electrochemical performance with minimal weight
3Manufacturing precision
If plasma spraying is used to deposit nanocrystals, then manufacturing precision and material utilization improve, but process complexity increases
Solution Approach 1:
The plasma spray apparatus is designed to perform multiple functions: it heats, atomizes, and deposits active materials in a single integrated process. The plasma jet simultaneously serves as the heat source, carrier gas flow, and deposition mechanism, reducing the need for separate processing equipment and simplifying the overall manufacturing process despite the advanced physics involved
Solution Approach 2:
The invention controls deposition precision by adjusting plasma parameters such as power, gas flow rate, and substrate distance. By optimizing these parameters, the process achieves controlled nanocrystal formation and uniform layer deposition without requiring excessively complex equipment, balancing manufacturing precision with process simplicity
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 allows for the creation of thinner, lighter, and more cost-effective lithium-ion batteries by forming electrochemically active nanocrystal layers on substrates, improving their performance and manufacturing efficiency.
Implementation Method 1
A plasma jet is used to heat and atomize a precursor solution, forming nanocrystals
Implementation Method 2
A plasma jet is used to heat and atomize a precursor solution
Implementation Method 3
The binder material is used to adhere active material particles to the current collector
Data Source
AI summary
A method and apparatus for forming an electrochemical layer of a thin film battery is provided. A precursor mixture comprising precursor particles dispersed in a carrying medium is activated in an activation chamber by application of an electric field to ionize at least a portion of the precursor mixture. The activated precursor mixture is then mixed with a combustible gas mixture to add thermal energy to the precursor particles, converting them to nanocrystals, which deposit on a substrate. A second precursor may be blended with the nanocrystals as they deposit on the surface to enhance adhesion and conductivity.