Three dimensional co-extruded battery electrodes

Patent metadata

Field	Value
Publication number	US-9793537-B2
Application number	US-201715435636-A
Country	US
Kind code	B2
Filing date	Feb 17, 2017
Priority date	Dec 27, 2012
Publication date	Oct 17, 2017
Grant date	Oct 17, 2017

Abstract

A three dimensional electrode structure having a first layer of interdigitated stripes of material oriented in a first direction, and a second layer of interdigitated stripes of material oriented in a second direction residing on the first layer of interdigitated stripes of material. A method of manufacturing a three dimensional electrode structure includes depositing a first layer of interdigitated stripes of an active material and an intermediate material on a substrate in a first direction, and depositing a second layer of interdigitated stripes of the active material and the intermediate material on the first layer in a second direction orthogonal to the first direction.

First claim

What is claimed is:

1. A method of manufacturing a three dimensional electrode structure, comprising:
depositing a first layer of contiguous, separated, interdigitated stripes of an active, electrode, paste material and an intermediate material on a substrate in a first direction, the intermediate material being one of either a liquid or gel electrolyte, or a porous material filled with electrolyte; and
depositing a second layer of contiguous, separated, interdigitated stripes of the active material on the first layer of interdigitated stripes of material and the intermediate material on the first layer in a second direction orthogonal to the first direction.

2. The method of claim 1 , further comprising:
removing the intermediate material from the first and second layers, leaving stripes of the active material with gaps between the stripes of active material; and
filling the gaps between the stripes of active material with an electrolyte.

3. The method of claim 2 , wherein removing the intermediate material comprises heating the structure to burn off the intermediate material.

4. The method of claim 1 , wherein depositing the first and second layers comprises passing the substrate past a co-extrusion print head multiple times.

5. The method of claim 1 , wherein depositing the first and second layers comprises depositing the layers with multiple passes of a co-extrusion print head past the substrate.

6. The method of claim 1 , wherein depositing the first and second layers comprises depositing the first layer with a first print head and the second layer with a second print head.

7. The method of claim 1 , wherein depositing the second layer comprises depositing the second layer with a different thickness than the first layer.

8. The method of claim 1 , wherein depositing the second layer comprises depositing the second layer with a different interdigitated pattern than the first layer.

9. The method of claim 1 , wherein depositing one of the first and second layers comprises depositing interdigitated stripes of active material wider than the intermediate material.

10. The method of claim 1 , wherein depositing one of the first and second layers comprise depositing interdigitated stripes of active material having a same width as the intermediate material.

Assignees

• Palo Alto Res Ct Inc

Inventors

• Cobb Corie Lynn
• Bae Chang-Jun

Classifications

• Y02E60/50

  Fuel cells · CPC title

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title

• H01M4/8882

  Heat treatment, e.g. drying, baking · CPC title

• H01M4/8864

  Extrusion · CPC title

• H01M4/8825

  Methods for deposition of the catalytic active composition · CPC title