Powder Layer Composite for Energy Devices Using Vibrated Squeegee
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Solution Overview
Problem
Existing powder layer composites for energy devices, such as all-solid-state batteries, face challenges in maintaining uniform weight per unit area and reducing solvent-induced deterioration, leading to variations in performance and quality.
Innovation Solution
A powder layer composite with a film thickness of 50 μm or more, containing a powder made of at least one type of particle material with a solvent concentration of 50 ppm or less, and a variation in weight per unit area of 10% or less in a 30 mm×30 mm region, achieved by using a squeegee vibrated at 2 kHz to 300 kHz to adjust the thickness and filling rate, ensuring a filling rate equal to or higher than the tap filling rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the powder layer thickness is increased to 50 μm or more to improve filling rate, then the powder filling density is improved, but the solvent concentration increases leading to deterioration
Solution Approach 1:
The patent controls the solvent concentration to be 50 ppm or less while maintaining a powder layer thickness of 50 μm or more. By precisely controlling the solvent parameter and using vibration to improve powder packing efficiency, the invention achieves high filling rate without the harmful effects of excessive solvent content
2Manufacturing precision
If a squeegee is used to adjust powder layer thickness, then the thickness control is improved, but the powder filling rate remains insufficient
Solution Approach 1:
By vibrating the squeegee at 2 kHz or more and 300 kHz or less during the thickness adjustment process, the invention simultaneously achieves precise thickness control and high powder filling rate. The vibration causes powder particles to settle densely and fill voids while the squeegee maintains the desired thickness profile
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 results in a stable and uniform powder layer with reduced voids, enhancing the output and quality of energy devices by minimizing variations in weight per unit area and preventing solvent-induced deterioration.
Implementation Method 1
adjusting a thickness of the powder layer and a filling rate of the powder in the powder layer by using the squeegee vibrated at a frequency of 2 kHz or more and 300 kHz or less
Data Source
AI summary
A powder layer composite includes a current collector, and a powder layer formed on the current collector and having a film thickness of 50 μm or more. The powder layer contains a powder made of at least one type of particle material. A concentration of a solvent contained in the powder layer is 50 ppm or less. A variation in a weight per unit area of the powder layer is 10% or less in an optional region with 30 mm×30 mm in the powder layer.