Structured Battery Electrodes via Solvent-Free Laser Powder Sintering
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Solution Overview
Problem
Existing lithium-ion battery manufacturing processes are costly, energy-intensive, and environmentally hazardous due to the use of solvents, and struggle to achieve homogeneous mixing of powder components for structured electrodes, affecting electrical performance and adhesion.
Innovation Solution
A solvent-free laser powder-bed fusion process using a CO2 laser to sinter a dry powder mixture of active materials, carbon black, and binders onto a metal substrate, with electrostatic spraying and selective laser scanning to form structured battery components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional solvent-based manufacturing processes are used, then ease of manufacture is improved, but manufacturing cost and environmental harm increase
Solution Approach 1:
The patent changes the physical state parameter of the binding medium from liquid (solvent-based) to solid (powder-based). This transformation eliminates the need for harmful organic solvents like NMP while maintaining the binding functionality, thereby reducing environmental harm without significantly compromising ease of manufacture
Solution Approach 2:
The invention utilizes phase transition by heating the solid powder mixture to melt the binder particles, creating a temporary liquid state that enables bonding. This controlled phase transition allows the process to achieve liquid-like bonding properties without using harmful liquid solvents throughout the entire manufacturing process
2Quantity of substance
If electrode thickness is increased to improve energy density, then energy density is improved, but power density decreases
Solution Approach 1:
The patent applies local quality by creating non-uniform powder distribution patterns where conductive material is concentrated in specific regions (at particle contacts and along transport pathways) rather than uniformly distributed. This localized enhancement of electrical conductivity enables thick electrodes to maintain high power density while achieving high energy density
Solution Approach 2:
The invention introduces carbon black particles as an intermediary conductive phase that facilitates electron transport between active material particles. This intermediary network of conductive pathways enables efficient charge transport through thick electrodes, decoupling the relationship between electrode thickness and power density
3Manufacturing precision
If homogeneous powder mixture is obtained for additive manufacturing, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent segments the mixing process into distinct stages: initial dry mixing of powders, followed by controlled binding through selective laser heating. This segmentation allows each stage to be optimized independently, achieving homogeneity without requiring complex integrated mixing equipment
Solution Approach 2:
The invention replaces complex mechanical mixing systems with a simplified approach using electrostatic spray deposition followed by laser-induced melting. The electrostatic field enables uniform powder distribution, while the laser provides localized heating for bonding, eliminating the need for complex mechanical mixers and reducing overall device 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 method reduces manufacturing costs and energy consumption, enhances electrical performance by ensuring homogeneous mixing and strong adhesion, and enables high-resolution, scalable production of high-power-density battery components.
Implementation Method 1
The powder deposition component comprises an electrostatic spray gun for imparting an electrical charge to the powder as the powder is discharged from a nozzle of the electrostatic spray gun
Implementation Method 2
A laser is used and configured to generate a laser beam to selectively sinter portions, or all, of the powder layer using a predetermined beam scanning pattern
Implementation Method 3
selectively sinter portions, or all, of the powder layer
Data Source
AI summary
The present disclosure relates to a method for creating a powder for use in a selective laser sintering additive manufacturing (AM) application to form a battery component. In one aspect the method may comprise providing a battery component active material, a carbon material and a binder material. The active material and the binder material are mixed together in a first ratio in a mixer for a first time period, to carry out a first mixing operation, to produce a first mixture of active material and binder material. Carbon material may then be added to the first mixture of active material and binder material in a second ratio. The carbon material and the first mixture of active material and binder material may then be mixed for a second time period in a second mixing operation to form a homogeneously mixed powder.