Woven Carbon Battery Electrode for Thick Porous Film Manufacturing
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Solution Overview
Problem
The existing wet process for manufacturing battery electrodes faces challenges in uniformly impregnating electrode slurry into thick, three-dimensional foam substrates, making mass production difficult and limiting energy density improvements.
Innovation Solution
A dry method is introduced, where a mixture of polymer powder and active material is formed into fibers, woven into a film, and carbonized to create a binder-free, high-conductivity electrode with a porous structure, capable of serving as both substrate and conductive material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wet process is used to manufacture battery electrodes, then electrode slurry can be coated on substrate, but uniform impregnation into thick three-dimensional foam substrates is difficult
Solution Approach 1:
The patent changes the physical state parameter of the electrode material from a liquid slurry (wet process) to a dry powder mixture, enabling uniform impregnation throughout thick substrates without the limitations of liquid coating methods
Solution Approach 2:
The patent replaces the chemical/wet coating process with a mechanical dry process involving powder mixing and extrusion, eliminating the fundamental limitation of liquid slurry penetration into thick three-dimensional structures
2Productivity
If wet process is used with solvents and binders, then electrode can be formed, but mass production becomes difficult and energy density improvement is limited
Solution Approach 1:
The patent extracts and eliminates the harmful components (solvents and binders) from the electrode manufacturing process, using only dry powder materials that can be directly processed without additional chemical additives
Solution Approach 2:
The electrode active material itself serves as the structural component, eliminating the need for separate binders to hold the electrode together, thereby simplifying the manufacturing process and enabling mass production
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 low-resistance, thick film electrodes with excellent electrolyte solution impregnability, improving energy density and facilitating mass production by eliminating the need for solvents and binders.
Implementation Method 1
obtaining a fiber by extruding the mixture of the polymer powder and the active material
Implementation Method 2
carbonizing the woven film
Data Source
AI summary
The present disclosure relates to a battery, and more particularly to a battery electrode. According to some implementations of the present disclosure, a method for manufacturing a battery electrode includes: forming a mixture of a polymer powder and an active material into a fiber; weaving the fiber into a woven film; and carbonizing the woven film.