Screen-Printed Battery Electrodes With Layered Porosity Control
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Solution Overview
Problem
The existing manufacturing process for energy storage devices, such as Li-ion batteries, is complex and time-consuming, requiring multiple discontinuous steps, including lengthy drying processes, which increases production lead time and costs.
Innovation Solution
A method using a screen printing process with multiple consecutive printing steps and controlled compressive forces to produce electrodes with tailored porosity distributions, allowing for continuous process control and reduced porosity variations between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes are used with multiple discontinuous steps and lengthy drying processes, then manufacturing precision can be maintained, but production time increases significantly
Solution Approach 1:
The patent implements a continuous screen printing process where multiple electrode layers are deposited and compressed in succession without interruption. The printing device applies different compressive forces during different printing steps to create varied porosity distributions across layers, eliminating the need for traditional discontinuous steps including lengthy drying processes in cabinets, thereby reducing production lead time while maintaining manufacturing precision
Solution Approach 2:
The patent changes the compression parameter dynamically during the printing process by applying different compressive forces in different printing steps. The first printing step applies a first compressive force to create a first porosity distribution, while the second printing step applies a second compressive force to create a second porosity distribution. This parameter variation enables precise control over electrolyte absorption characteristics without requiring extended drying times
2Ease of manufacture
If traditional screen printing with single layer deposition is used, then process simplicity is maintained, but electrolyte absorption control is insufficient
Solution Approach 1:
The patent segments the electrode structure into multiple layers deposited in successive printing steps, with each layer having distinct porosity characteristics controlled by different compressive forces. This segmentation allows precise tailoring of electrolyte absorption at different electrode regions while maintaining the simplicity of the screen printing process itself
Solution Approach 2:
The patent applies local quality by creating different porosity distributions in different layers of the electrode. The first layer has a first porosity distribution optimized for certain electrolyte absorption characteristics, while the second layer has a second porosity distribution optimized for other characteristics. This local differentiation enables precise control over overall electrolyte absorption while using the same screen printing process
3Manufacturing precision
If multiple discontinuous manufacturing steps are used, then manufacturing precision can be achieved, but device complexity increases
Solution Approach 1:
The patent merges multiple manufacturing operations into a single continuous screen printing process. Deposition of multiple electrode layers and application of different compressive forces are combined in one uninterrupted printing sequence, eliminating the need for separate drying cabinets and handling steps. This consolidation maintains electrode structure control precision while significantly reducing manufacturing process complexity
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 simplifies the production of electrodes, reduces lead time, and enables more precise control over electrolyte absorption, enhancing the efficiency and cost-effectiveness of energy storage device manufacturing.
Implementation Method 1
a pressing force is then applied to the first portion of the electrode paste by means of a pressing device (2) to compress the first portion of the electrode paste
Data Source
Figure 1~6
Figure 7~9c
AI summary
A method for producing an electrode (1) for an energy storage device using a screen printing process comprises at least two successive printing steps. In a first printing step, a first portion of an electrode paste (9) is applied to a substrate (3). Subsequently, a pressure force is applied to the first portion of the electrode paste (9) by means of a press (2) to compact it, resulting in a compacted first portion of the electrode paste forming a first sublayer (11). In a second printing step, a second portion of the electrode paste is applied to the first sublayer (11), and a pressure force is subsequently applied to the second portion of the electrode paste to compact it, resulting in a compacted second portion of the electrode paste forming a second sublayer (12).