Solid-State Electrode Fiber Networks Without VOC Solvents
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Solution Overview
Problem
Existing solid-state battery formation techniques rely on volatile organic compounds (VOCs) as solvents, which pose environmental and safety risks, and there is a need for high-performance solid-state battery electrodes formed via solvent-free manufacturing processes.
Innovation Solution
A solvent-free method is employed to create a solid-state electrode with a fibrous polymeric network containing electroactive material, solid-state electrolyte, and porous fibrillation particles, using polytetrafluoroethylene (PTFE) fibers and activated carbon, forming a film through mixing and consolidation under pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If solvent-free methods are used to form solid-state electrodes, then environmental safety and manufacturing cleanliness are improved, but the difficulty of achieving high-performance electrode formation increases
Solution Approach 1:
The patent introduces porous fibrillation particles as intermediary substances that facilitate the formation of fibrous polymeric networks in solvent-free conditions. These particles act as mediators between the solid particles and the polymeric binder, enabling network formation without requiring VOCs while maintaining electrode performance
Solution Approach 2:
The patent changes the physical state parameters of the electrode formation process by eliminating liquid solvents and operating entirely in the solid state. This involves controlling parameters such as particle size distribution, porosity, and mechanical consolidation conditions to achieve proper network formation without liquid media
2Manufacturing precision
If fibrous polymeric networks are formed without solvents, then manufacturing precision and structural integrity are improved, but the ease of manufacture decreases
Solution Approach 1:
The patent employs preliminary action by pre-forming fibrous polymeric networks using porous fibrillation particles before final electrode consolidation. This preliminary structuring enables precise control of the electrode architecture while simplifying the overall manufacturing process by separating network formation from consolidation steps
Solution Approach 2:
The patent utilizes porous fibrillation particles to create fibrous polymeric networks with controlled porosity. These porous structures enable precise control of electrode morphology, fluid pathways, and mechanical properties while maintaining ease of manufacture through straightforward mixing and consolidation processes
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 method produces a high-performance solid-state electrode that reduces environmental impact, enhances safety, and maintains electrochemical efficiency without the use of VOCs.
Implementation Method 1
a fibrous polymeric network including polymer fibers having an average diameter of greater than or equal to about 20 nanometers to less than or equal to about 300 nanometers
Implementation Method 2
The clusters are consolidated under pressure to form a film including a fibrous polymeric network having the plurality of solid particles distributed therein
Data Source
AI summary
In various aspects, the present disclosure provides solvent-free methods of making a solid-state electrode active layer for a solid-state electrode in an electrochemical cell that cycles lithium ions, by using a plurality of solid polymeric binder particles capable of fibrillation with porous fibrillation particles with a first shear force to at least partially fibrillate the solid polymeric binder particles to form a polymeric binder mixture. The disclosure also contemplates a current collector and a porous active layer disposed thereon. The porous active layer includes a fibrous polymeric network having a plurality of solid particles distributed therein. The solid particles may include electroactive material particles, solid-state electrolyte particles, and porous fibrillation particles.