Paste-Type Silicon Anode Coating for Scalable Proton Batteries
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Solution Overview
Problem
The dry compression molding process for producing silicon-based anodes in proton conductive secondary batteries is inefficient, as it is difficult to adjust the electrode thickness, generates significant processing waste, and is not suitable for mass production, especially when using a metal foil substrate or flammable materials.
Innovation Solution
A paste electrode is developed using a wet-laid process, comprising active material powder from group 14 elements, a binder, and a substrate, allowing for adjustable thickness and reduced waste, facilitating mass production and effective charge/discharge performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dry compression molding process is used to produce silicon-based anodes, then the anode can be manufactured, but it is difficult to adjust the electrode thickness to a predetermined value and generates significant processing waste
Solution Approach 1:
The patent changes the manufacturing process from dry compression molding to a wet-based coating process where a slurry containing silicon powder and binder is applied to a substrate. This allows precise control of electrode thickness by controlling the slurry application parameters and drying conditions, eliminating the waste generation inherent in dry compression molding
Solution Approach 2:
The patent replaces the mechanical dry compression molding process with a wet-based coating and drying process. The slurry is applied to the substrate and then dried to form the electrode, substituting the mechanical compression method with a chemical-physical drying process that enables better thickness control and reduces waste
2Productivity
If dry compression molding process is used, then the anode can be produced, but the process is not suitable for mass production of proton conductive secondary batteries
Solution Approach 1:
The patent transforms the manufacturing approach by using a wet-based slurry coating process that can be easily scaled for mass production. The process parameters such as slurry viscosity, coating speed, and drying conditions can be optimized for high-volume production, making it suitable for manufacturing proton conductive secondary batteries at scale
Solution Approach 2:
The patent creates a versatile manufacturing process that can accommodate various substrate types (metal foils, flammable materials) and electrode configurations. The wet-based coating method is universally applicable to different battery designs and materials, enhancing ease of manufacture across multiple product types
3Adaptability or versatility
If dry compression process is used, then the anode can be manufactured, but it cannot be used when a metal foil is used as a substrate or when the electrode material contains flammable material
Solution Approach 1:
The patent replaces the mechanical dry compression process with a wet-based coating and drying process. This substitution allows the use of metal foil substrates and flammable materials because the wet process involves liquid slurry application and controlled drying, avoiding the high mechanical pressures and potential sparks associated with dry compression molding
Solution Approach 2:
The patent changes the manufacturing parameters from dry mechanical compression to wet coating and thermal drying. This parameter change enables compatibility with a broader range of substrate materials including metal foils and flammable materials, as the process conditions can be controlled to be gentle and chemically compatible with these materials
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 paste electrode enables mass production of proton conductive secondary batteries with satisfactory charge/discharge performance, reducing machining waste and accommodating various battery types, including those with metal foils or flammable materials.
Implementation Method 1
a paste electrode for use as an anode of a proton conductive secondary battery, the paste electrode including: an active material powder containing a group 14 element as a predominant component; a binder; and a substrate with a mixture applied thereon, the mixture containing the active material powder and the binder. A paste electrode according to this configuration, which is produced using a wet-laid process
Implementation Method 2
It has been known that some materials of metal hydride alloys such as nickel hydroxide can absorb and desorb hydrogen. Such hydrogen storage materials can be used as cathode materials
Data Source
AI summary
A paste electrode for use as an anode of a proton conductive secondary battery includes: an active material powder containing a group 14 element as a predominant component; a binder; and a substrate with a mixture applied thereon, the mixture containing the active material powder and the binder. The mixture may contain one or more conductive additives. The active material powder may contain silicon as the group 14 element.