Sprayed Li-Ion Battery Electrodes Without Solvent Drying
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Solution Overview
Problem
Conventional rechargeable battery manufacturing methods rely on solvent-based approaches that are toxic and environmentally hazardous, limiting battery size, geometry, and energetic properties, and requiring the use of planar current collectors.
Innovation Solution
A solvent-less manufacturing method employing high-velocity particle spraying to form agglomerations of active materials and metallic binders, eliminating the need for solvents and planar current collectors, allowing for customized battery geometries and higher performance through conformal contact between particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solvent-based tape casting method is used, then battery electrodes can be manufactured with conventional processes, but toxic solvents require handling and disposal creating environmental hazards
Solution Approach 1:
The patent extracts and eliminates the solvent component from the conventional tape casting process, transitioning to a dry powder mixing and spraying method that forms electrode materials without requiring solvent binding, thereby removing the environmental hazard while maintaining manufacturability
Solution Approach 2:
The invention changes the physical state parameters of the manufacturing process from liquid slurry (requiring solvent) to dry powder form, altering the process from wet chemical handling to mechanical spraying and sintering, which eliminates toxic solvent exposure while preserving electrode formation capability
2Device complexity
If planar current collectors are used in conventional battery construction, then electrode assembly is simplified, but battery size, geometry, and energetic properties are limited
Solution Approach 1:
The patent replaces static planar current collectors with dynamically formable sprayed electrode structures that can be deposited in various geometries directly onto collectors or as free-standing components, enabling adaptable battery shapes while maintaining assembly simplicity through the spraying process
Solution Approach 2:
The invention transitions from two-dimensional planar electrode deposition to three-dimensional sprayed particle agglomerations that can form complex geometries and non-planar structures, expanding battery design possibilities while maintaining manufacturing efficiency through the spraying process
3Productivity
If high velocity particle spraying is used, then battery capacity and charge/discharge rates improve, but manufacturing process complexity increases
Solution Approach 1:
The patent replaces conventional mechanical electrode fabrication methods (mixing, spreading, calendaring) with a mechanical spraying system that uses high-velocity particle delivery to form electrodes, achieving superior performance through controlled particle impact and agglomeration while consolidating multiple process steps into one
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 method enables the production of high-capacity batteries with improved charge/discharge rates and reduced heating, capable of custom-sized designs without the use of toxic solvents or inactive materials, while minimizing environmental impact.
Implementation Method 1
forms charge material layers from kinetic energy of high velocity particles impelled into an aggregation such that bombardment of the particles against other particles in the aggregation forms a charge conveying structure having a suitable structure and density for high performance charge flow
Implementation Method 2
High velocity bombardment from a carrier gas nozzle therefore accumulates an active charge material (active material) and conductive binder in a layered arrangement for the finished battery
Implementation Method 3
spraying the agitated particulate mixture for forming a multi-layer thickness... accelerating the particulate mixture for conformal communication between the particles in the particulate mixture to promote charge flow
Data Source
AI summary
A rechargeable lithium-ion (Li-ion) battery employs a low temperature approach to battery manufacturing that forms charge material from kinetic energy of high velocity particles impelled into an aggregation such that bombardment of the particles against other particles in the aggregation forms a charge conveying structure. High velocity bombardment from a carrier gas nozzle accumulates an active charge material in a layered arrangement for the finished battery. Preparation of the particles, such as by ball milling or spraydrying, arranges particle agglomerations. The particle agglomerations, when impelled against other agglomerations or a current collector, forms a layer of cathodic, anodic or electrolytic battery material. The metallic binder conveys charge for mitigating or eliminating a need for a planar current collector underlying the sprayed layer. The resulting layers are suitable for battery operation, and are manufactured in an absence of any solvent drying or disposal.