Structured Screen-Printed Electrodes for Fast-Charging Thick Layers
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Solution Overview
Problem
Existing methods for producing electrodes for energy storage devices, such as lithium-ion batteries, require additional steps and equipment to introduce structuring, leading to inefficiencies and losses in active material, particularly when using thick layers which hinder rapid charging capabilities.
Innovation Solution
A screen printing process is used to apply electrode paste with closed screen openings, creating cavities and microstructures without the need for additional steps, allowing for precise control of porosity and structuring within the electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If additional structuring steps are applied to electrodes, then rapid charging capability is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent combines the electrode paste application process with the structuring process into a single screen printing operation. The screen's closed openings create cavities and microstructures in the electrode paste simultaneously as the paste is applied, eliminating the need for separate structuring steps and reducing manufacturing complexity while maintaining rapid charging capability
Solution Approach 2:
The screen printing process performs the structuring action in advance during electrode manufacturing. By using a screen with closed openings, the desired cavity structure is created during the initial paste application, so no additional structuring steps are needed later in the manufacturing process
2Manufacturing precision
If additional structuring equipment is used, then electrode microstructure is improved, but manufacturing cost and material loss increase
Solution Approach 1:
The screen printing device performs multiple functions simultaneously: it applies the electrode paste to the substrate and creates the microstructure with cavities in a single operation. The screen with closed openings serves both as a paste application template and as a structuring tool, eliminating the need for separate structuring equipment and reducing active material loss that would occur with additional processing steps
3Quantity of substance
If thick electrode layers are used, then energy density is improved, but lithium-ion transport pathways become longer and charging speed decreases
Solution Approach 1:
The screen printing process with closed openings creates a segmented or structured electrode paste layer with distributed cavities and microstructures. This segmentation reduces the effective transport distance for lithium ions within the thick electrode layer, allowing high energy density to be maintained while improving charging speed by creating shorter diffusion pathways through the structured architecture
Data Source
Figure 1~3
Figure 4~5b
Figure 6~8b
AI summary
According to a method for producing an electrode (50) for an energy storage device using a screen printing device (2), an electrode paste (1) is applied to a substrate (3) by means of the screen printing device (2). The screen printing device (2) includes a screen (4) for receiving the electrode paste (1), wherein the electrode paste (1) is applied to the substrate (3) through the screen (4) by means of a pressing element (5). The screen (4) includes screen openings (6), wherein at least one of the screen openings (6) is designed as a closed screen opening (7) such that the electrode paste (1) acquires a structure (8) when it is printed through the screen (4) onto the substrate (3), resulting in a printed electrode paste (10).The closed sieve opening (7) prevents the flow of the electrode paste (1) through the sieve (4) at the point which contains the closed sieve opening (7), so that a cavity (9) is formed in a region of the printed electrode paste (10).