Printed Electrolyte Layers for High-Speed Flexible Cell Manufacturing
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Solution Overview
Problem
Existing methods for producing flexible and thin electrochemical cells face challenges in achieving high volume manufacturing with low cost and high performance, particularly due to difficulties in achieving low viscosity inks with sufficient active material loading and ensuring airtight seals and compatibility with high-speed printing processes.
Innovation Solution
A method using inks comprising a solvent and an active-layer-forming material with a polymeric binder, suitable for high-speed printing processes like flexographic printing, which includes electrodes and electrolytes, allowing for the formation of robust and flexible layers suitable for thin and flexible electrochemical cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed printing methods are used, then productivity is improved, but the ink viscosity must be low which limits the thickness of printable layers
Solution Approach 1:
The patent changes the rheological parameters of the ink by using a shear-thinning fluid with specific viscosity characteristics. The ink has a viscosity of 10-1000 cP at shear rates of 100-10000 s^-1, allowing it to flow easily during high-speed printing while maintaining sufficient thickness after deposition. This parameter optimization enables printable layers of 10-100 microns thickness compatible with high-speed processes.
Solution Approach 2:
The patent uses composite ink formulations containing polymer binders (such as PVDF, CMC, or SBR), conductive additives (carbon black, graphite, or carbon nanotubes), and active materials suspended in a solvent matrix. This composite structure provides both the flow characteristics needed for high-speed printing and the structural integrity for forming robust electrodes of controlled thickness.
2Ease of manufacture
If low viscosity inks are used for high-speed printing, then ease of manufacture is improved, but active material loading becomes insufficient
Solution Approach 1:
The patent optimizes the concentration parameters of active materials in the ink formulation, achieving loadings of 5-50 wt% while maintaining printability. The shear-thinning behavior and controlled viscosity allow sufficient active material to be incorporated without compromising the ink's flow characteristics during high-speed deposition.
Solution Approach 2:
The composite ink system uses polymer binders to stabilize high concentrations of active materials and conductive additives. The binder matrix holds the active material particles uniformly distributed, enabling high loading content while maintaining the ink's processability and preventing aggregation or settling during storage and printing.
3Weight of moving object
If thin and flexible cells are produced, then weight is reduced, but ensuring airtight seals and preventing ingress of external species becomes more difficult
Solution Approach 1:
The patent employs flexible polymer substrates and thin-film deposition techniques to create lightweight cell structures. The flexible nature of these thin films allows them to conform to various shapes while maintaining integrity, and when properly sealed at edges and interfaces, they provide effective barriers against external species ingress.
Solution Approach 2:
The use of composite materials with appropriate chemical resistance and mechanical properties ensures that thin flexible components maintain seal integrity. The polymer binders and encapsulation materials are selected to be chemically inert and impermeable to electrolyte leakage or external contaminant ingress, providing reliable sealing in thin-cell configurations.
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
Enables the rapid and efficient production of flexible electrochemical cells with high performance and low cost, using inks that maintain active material loading and ensure airtight seals, facilitating high-speed printing and compatibility with various cell formats.
Implementation Method 1
The active material in suspension in the solvent; and a polymeric binder
Implementation Method 2
printing the ink layer to form the active layer
Implementation Method 3
allowing the ink layer to dry or cure to form the active layer
Data Source
AI summary
A method of printing an electrolyte for an electrochemical cell, the method comprising: providing an ink, the ink comprising a solvent and an electrolyte-forming material, the electrolyte-forming material comprising an electrolyte species and a polymer: printing the ink onto a medium to form an ink layer on the medium; allowing the ink to dry or cure to cause the electrolyte forming material to form an electrolyte layer on the medium. Also provided are electrodes made using the method, electrolytic cells comprising the electrodes and articles comprising the electrolytic cells.