DESC:FORM 2

THE PATENTS ACT, 1970

(39 of 1970)

&

THE PATENT RULES, 2003

COMPLETE SPECIFICATION

[See Section 10 and Rule 13]

TITLE:

“A DEVICE TO FABRICATE THREE-DIMENSIONAL
ELECTRODE”

APPLICANT:

E-TRNL ENERGY PRIVATE LIMITED
a company incorporated under Indian Companies Act, 2013,
having address at
Plot No. 08, SY No. 75, Sadaramangala lndustrial Area, M.D. Pura White Field, Mahadevapura, Bengaluru, Bengaluru Urban, Pin Code – 560048, Karnataka, India

PREAMBLE TO THE DESCRIPTION:
The following specification particularly describes the invention and the manner in which it is to be performed:

FIELD OF THE INVENTION
The present invention relates to a field of three-dimensional electrode. More particularly, the present invention relates to a device to fabricate three-dimensional electrode with blind holes array architecture.

BACKGROUND OF THE INVENTION
A battery is an electrochemical cell that converts chemical energy into electrical energy and electrodes of the batteries play a crucial role in conversion of chemical energy into electrical energy. The electrodes produce electrical energy by means of a chemical reaction, typically involving the movement of electrons from one electrode to another through an electrolyte.
There are two types of electrode based on the structure, two dimensional electrode and three dimensional electrode. Two dimensional electrodes are flat and have a surface area that is limited to their two-dimensional plane and three dimensional electrodes have a three-dimensional structure which provides them with a much larger surface area than two dimensional electrode. The larger surface area provides increased electrochemical activity than two dimensional electrodes.
Three dimensional electrodes offer the potential to achieve higher energy density without sacrificing power density or a small footprint. By extending the length of the vertical rods of the electrodes, the surface area is increased, allowing for more charge storage. However, increasing the length of the rods also increases the ohmic resistance along the rods, which can limit the battery's performance. The optimal length of the rods is determined by a combination of factors, including the ionic conductivity of the electrolyte, electrode geometry, and the electronic and ionic conductivity of the electrode materials.
The fabrication of three-dimensional electrodes involves amplifying the surface area of a thin-film battery. This method utilizes micromachining techniques to create precisely dimensioned holes or trenches in silicon or glass substrates, effectively increasing their surface area. Subsequently, thin films of the various battery components, including current collectors, electrode materials, and electrolyte, are conformally deposited onto the three-dimensional substrate.
Another approach includes fabrication of three dimensional electrode in interdigitated and concentric arrangements that allows for complete utilization of the electrode volume. The configurations involve interdigitated rods or plates of each electrode, with the electrolyte filling the remaining space. The concentric configuration, exhibits higher energy density than the interdigitated configuration due to its more efficient electrolyte utilization. However, this fabrication strategy presents two crucial considerations. Firstly, the energy density is directly proportional to the height of the rods or plates, which is constrained by the ohmic resistance of the electrode. Secondly, in order to maximize energy density, the batteries requires to minimize the volume occupied by the electrolyte. This necessitates the development of conformal electrolytes, which adhere tightly to the electrode surfaces and reduce electrolyte volume.
CN111326740B discloses a perforating device and a perforating method for preparing a porous electrode plate, wherein the length of a puncture needle of the perforating device and the minimum distance between a puncture needle fixing part and an electrode plate supporting part are less than or equal to L-L and less than or equal to 5000 microns1Less than or equal to 5000 µm, when L is more than or equal to L1. The punching device punches the electrode plate to form a through hole structure; when L < L1And the punching device punches the electrode plate to form a blind hole structure. The perforating device can be used for preparing the electrode plate with the through hole structure, the electrode plate with the blind hole structure and the electrode plate with the through hole structure and the blind hole structure, so that the diversity of the porous structure is ensured, an ion channel is provided for pre-embedded lithium, the electrolyte infiltration speed and infiltration uniformity of the electrode plate are improved, and the perforating device plays a key role in improving the performance (such as cycle life, rate characteristic, capacity, lithium deposition prevention to improve the safety performance of a battery and the like) of an energy storage device formed by the porous electrode. However, this invention fails to provide a device to manufacture the three dimensional electrode in scalable quantities, and these devices are not economical due to their high manufacturing cost.
CN111326740B discloses roll forming method of porous metal foil and coiled porous metal foil formed by the same comprises a long metal foil wound into a coil shape is rewound, and the long metal foil is sandwiched between a forming roll and a receiving roll to form a large number of fine through holes in the metal foil, and after forming the fine through holes. A roll forming method of a porous metal foil in which a long metal foil is wound up again in a coil shape, and in the forming roll, a large number of fine punched convex shapes are formed over the entire circumference of the circumferential roll surface. The receiving roll is a roll formed of an elastic body surface which is pressed against and elastically deformed in a face-to-face manner with respect to the punched convex surface of the forming roll, and the long metal foil is formed on the punched convex surface of the molding roll. On the other hand, the long metal foil is held in a state of being bitten against the pull-out mold on the surface of the forming roll so that the long metal foil is bitten and introduced at the biting position A and separated at the separated position C. Together with the forming roll. The plurality of fine punched through holes are formed by rolling between the molding roll and the receiving roll, and burrs are generated by the fine punched through holes, and the molding roll surface is produced. The scraps of the long metal foil punched and formed by the punched convex mold formed in the above are left on the receiving roll, and the scraps left on the receiving roll are provided to the receiving roll. It is made to remove from the elastic body surface of the receiving roll concerned by the rotating brush, and the embossing which is not penetrated is given to the portion where the penetration hole of the above-mentioned long metal foil is not formed, and the embossed portion. The drawback associated with this invention is that the device is not capable of making a desired optimal depth hole in an electrode material which increases the ohmic resistance in the rods.
Therefore, there is need for a device to fabricate three dimensional electrode that efficiently punches the hole to the optimal depth in the electrode material, capable of manufacturing the three dimensional electrode in a scalable quantity and provides the economical device to fabricate three dimensional electrode.

OBJECT OF THE INVENTION
The main object of the present invention is to provide a device to fabricate three-dimensional electrode with blind holes array architecture.
Another object of the present invention is to provide a device to fabricate three-dimensional electrode in scalable quantity.
Yet another object of the present invention is to provide a device to fabricate three-dimensional electrode which is economical.
Yet another object of the present invention is to provide a device to fabricate three-dimensional electrode which include a flat punch to flatten the electrode material in a die.
Yet another object of the present invention is to provide a device to fabricate three-dimensional electrode which include a pin punch to punch array of holes in the flattened the electrode material in a die.
Still another object of the present invention is to provide a device to fabricate three-dimensional electrode that efficiently punches the hole to the optimal depth in the electrode material.

SUMMARY OF THE INVENTION
The present invention relates to a device to fabricate three-dimensional electrode with blind holes array architecture.
In an embodiment, the present invention provides a device to fabricate three-dimensional electrode comprises a device to fabricate three-dimensional electrode comprises a press machine, an upper platform, a lower press plate, and a drive system. The press machine includes said upper platform having an upper flat punch platform and an upper pin punch platform linearly aligned to each other on said upper platform of said press machine and said lower press plate is movably secured beneath said upper platform. The device includes a flat punch that is coupled to an upper punch press plate and said upper punch press plate is coupled to the lower portion of said upper flat punch platform of said press machine and facilitates in the flat punching action on the electrode material. The device includes a pin holder assembly coupled to the lower portion of said upper pin punch platform of said press machine and configured to facilitate in a pin punching action on the electrode material. The device includes a base plate coupled to the upper portion of said lower press plate of said press machine through a plurality of base fastener and said base plate has a central cylindrical portion with said electrode die secured over said central cylindrical portion through a plurality of die fastener and said electrode die has a central cavity for holding the electrode material therein. The lower press plate is connected to said drive system configured to move said lower press plate in up, down, forward and backward direction for flat and pin punching action on the electrode material placed on said electrode die.
The above objects and advantages of the present invention will become apparent from the hereinafter set forth brief description of the drawings and detailed description of the invention appended herewith.

BRIEF DESCRIPTION OF THE DRAWING
An understanding of a device to fabricate three-dimensional electrode of the present invention may be obtained by reference to the following drawings:
Figure 1 is a front view of a device to fabricate three-dimensional electrode according to an embodiment of the present invention.
Figure 2 is a top view of a device to fabricate three-dimensional electrode according to an embodiment of the present invention.
Figure 3 is a perspective view of a flat punch according to an embodiment of the present invention.
Figure 4 is an exploded view of a pin punch according to an embodiment of the present invention.
Figure 5 is a perspective view a device punching the array of holes to fabricate three-dimensional electrode according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described hereinafter with reference to the accompanying drawings in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough, and will fully convey the scope of the invention to those skilled in the art.
Many aspects of the invention can be better understood with references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings. Before explaining at least one embodiment of the invention, it is to be understood that the embodiments of the invention are not limited in their application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The embodiments of the invention are capable of being practiced and carried out in various ways. In addition, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
In an embodiment, the present invention provides a device to fabricate three-dimensional electrode comprises a press machine, an upper platform, a lower press plate, and a drive system. The press machine includes said upper platform having an upper flat punch platform and an upper pin punch platform linearly aligned to each other on said upper platform of said press machine and said lower press plate is movably secured beneath said upper platform. The device includes a flat punch that is coupled to an upper punch press plate and said upper punch press plate is coupled to the lower portion of said upper flat punch platform of said press machine and facilitates in the flat punching action on the electrode material. The device includes a pin holder assembly coupled to the lower portion of said upper pin punch platform of said press machine and configured to facilitate in a pin punching action on the electrode material. The device includes a base plate coupled to the upper portion of said lower press plate of said press machine through a plurality of base fastener and said base plate has a central cylindrical portion with said electrode die secured over said central cylindrical portion through a plurality of die fastener and said electrode die has a central cavity for holding the electrode material therein. The lower press plate is connected to said drive system configured to move said lower press plate in up, down, forward and backward direction for flat and pin punching action on the electrode material placed on said electrode die.
Referring to Figure 1, a front view of a device to fabricate three-dimensional electrode according to an embodiment of the present invention is depicted. The device to fabricate three dimensional electrode comprises a press machine (22), an upper platform (23), a lower press plate (7) and a drive system (27). The press machine (22) includes said upper platform (23) having an upper flat punch platform (24) and an upper pin punch platform (25) linearly aligned to each other. The lower press plate (7) is movably secured beneath said upper platform (23).
The lower press plate (7) is connected to said drive system (27) to move said lower press plate (7) in up, down, forward and backward direction for flat and pin punching action on the electrode material placed on said electrode die (5). The drive system (27) includes but not limited to an electric motor, a hydraulic actuator, or a pneumatic actuator.
The device has an upper punch press plate (16) coupled to the lower portion of said upper flat punch platform (24) of said press machine (22). The upper punch press plate (16) has a flat punch (17) coupled to said upper punch press plate (16). The flat punch (17) facilitates in the flat punching action on the electrode material.
The device has a pin holder assembly (26) coupled to the lower portion of said upper pin punch platform (25) of said press machine (22) and configured to facilitate in a pin punching action on the electrode material.
The upper portion of said lower press plate (7) is coupled to a base plate (6) of said press machine (22) through a plurality of base fastener (13). The base plate (6) has a central cylindrical portion (19) with an electrode die (5) secured over said central cylindrical portion (19) through a plurality of die fastener (12) and said electrode die (5) has a central cavity (20) for holding the electrode material therein.
Referring to Figure 2, a top view of a device to fabricate three-dimensional electrode according to an embodiment of the present invention is depicted. The device to fabricate three dimensional electrode has an upper platform (23) having an upper flat punch platform (24) and an upper pin punch platform (25) linearly aligned to each other on said upper platform (23) of said press machine (22). The lower press plate (7) is movably secured beneath said upper platform (23). The lower press plate (7) moves between said upper flat punch platform (24) and said upper pin punch platform (25) through a drive system (27) for flat and pin punching action in an electrode material.
Referring to Figure 3, a perspective view of a flat punch according to an embodiment of the present invention is depicted. The three-dimensional electrode fabricating device includes a flat punch (17) coupled to an upper punch press plate (16) and said upper punch press plate (16) is coupled to the lower portion of a upper flat punch platform (24) of a press machine (22) and facilitates in the flat punching action on the electrode material. The flat punch (17) is coupled to the lower central portion of said upper punch press plate (16) through a plurality of punch press plate fastener (18). The shape of said flat punch (17) is of any polygonal shape such as triangle, square, pentagon, hexagon etc.
The device has a lower press plate (7) and a base plate (6). The base plate (6) coupled to the upper portion of said lower press plate (7) through a plurality of base fastener (13). The base plate (6) has a central cylindrical portion (19) with an electrode die (5) secured over said central cylindrical portion (19) through a plurality of die fastener (12) and said electrode die (5) has a central cavity (20) for holding the electrode material therein. The shape of said central cavity (20) is of any polygonal shape such as triangle, square, pentagon, hexagon etc.
Referring to Figure 4, an exploded view of a pin punch of a device to fabricate three-dimensional electrode according to an embodiment of the present invention. The device includes a pin holder assembly (26) coupled to the lower portion of an upper pin punch platform (25) of a press machine (22). The pin holder assembly (26) is configured to facilitate in a pin punching action on the electrode material.
The pin holder assembly (26) comprises an upper pin press plate (4), a pin holder (1), a plurality of spring (15) and an ejector plate (3). The upper pin press plate (4) attached to said upper pin punch platform (25) of said press machine (22).
The pin holder (1) is coupled to the lower central portion of said upper pin press plate (4) through a plurality of pin fastener (9) and a plurality bolts (10). The pin holder (1) has a pin punch (2) with an array of pins provided to punch an array of holes in the electrode material placed in a central cavity (20) and shape of the array of pin of said pin punch (2) is of any polygonal shape such as triangle, square, pentagon, hexagon etc.
The plurality of spring (15) is secured between said upper pin press plate (4) and said ejector plate (3) through a plurality of pin fastener (8) and a plurality bolts (10). The plurality of spring (15) facilitates in spring back action of said ejector plate (3) after punching the array of holes in the electrode material.
The ejector plate (3) has a ejector plate cavity (21) provided to allow said pin punch (2) to pass through said ejector plate (3) and punch the holes in electrode material placed in said central cavity (20).
The device includes a base plate (6) coupled to the upper portion of a lower press plate (7) of said press machine (22) through a plurality of base fastener (13) and said base plate (6) has a central cylindrical portion (19) with said electrode die (5) secured over said central cylindrical portion (19) through a plurality of die fastener (12) and said electrode die (5) has a central cavity (20) for holding the electrode material therein. The lower press plate (7) is connected to a drive system (27) configured to move said lower press plate (7) in up, down, forward and backward direction for flat and pin punching action on the electrode material placed on said electrode die (5).

EXAMPLE
Working of the invention
The device to fabricate three dimensional electrode, comprises a press machine (22), an upper platform (23), a lower press plate (7) and a drive system (27). The press machine (22) includes said upper platform (23) having an upper flat punch platform (24) and an upper pin punch platform (25) linearly aligned to each other. The upper flat punch platform (24) has a flat punch (17) for flat punching action and the upper pin punch platform (25) has a pin holder (1) for pin punching action in the electrode material.
The device has a base plate (6) attached to said lower press plate (7) of said press machine (22). The base plate (6) has a central cylindrical portion (19) with an electrode die (5) and a central cavity (20) in said electrode die (5) for holding the electrode material therein.
The electrode material which is to be fabricated into the three dimensional electrode is placed in said central cavity (20). The base plate (6) which is attached to said lower press plate (7) and connected to said drive system (27) to move said lower press plate (7) in up, down, forward and backward direction for flat and pin punching action.
When flat punch press has to be done in the electrode material said drive system (27) moves said base plate (6) under said upper flat punch platform (24) and lifts the electrode material placed in said central cavity (20) upwards for flat punching action. The upward force from said drive system (27) presses the electrode material against the said flat punch (17) and facilitates in the flattening of the electrode material placed in said central cavity (20).
Once, the flattening of the electrode material is done, said drive system (27) moves said base plate (7) under said upper pin punch platform (25) for the pin punching action (as shown in Figure 5). The drive system (27) lifts the flattened electrode material upwards for pin punching action. The upward force from said drive system (27) against said pin holder (1) facilitates in pin punching action of the electrode material placed said the central cavity (20). During the punching of said pin holder (1) into flat electrode material, said plurality of spring (15) placed between the ejector plate (3) and said upper pin press plate (4) is compressed allowing the pin punch (2) to pass through the ejector plate cavity (21) and punches the holes in electrode material placed in the electrode die (5). After, getting the desired hole depth into the electrode material, said plurality of spring (15) retract said ejector plate (3) to its original position. The punching of the pin punch (2) is repeated until the optimal required depth of the hole is achieved to obtain the three-dimensional electrode.
Therefore, the present invention provides a device to fabricate three dimensional electrode that efficiently punches the hole to the optimal depth in the electrode material, capable of manufacturing the three dimensional electrode in a scalable quantity and provides the economical device to fabricate three dimensional electrode.
Many modifications and other embodiments of the invention set forth herein will readily occur to one skilled in the art to which the invention pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
The foregoing description of embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principals of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
,CLAIMS:CLAIMS

We claim:
1. A device to fabricate three dimensional electrode, comprising;
a press machine (22);
an upper platform (23);
a lower press plate (7); and
a drive system (27);
wherein:
said press machine (22) includes said upper platform (23) having an upper flat punch platform (24) and an upper pin punch platform (25) linearly aligned to each other on said upper platform (23) of said press machine (22) and said lower press plate (7) is movably secured beneath said upper platform (23);
said device includes a flat punch (17) that is coupled to an upper punch press plate (16) and said upper punch press plate (16) is coupled to the lower portion of said upper flat punch platform (24) of said press machine (22) and facilitates in the flat punching action on the electrode material;
said device includes a pin holder assembly (26) coupled to the lower portion of said upper pin punch platform (25) of said press machine (22) and configured to facilitate in a pin punching action on the electrode material;
said device includes a base plate (6) coupled to the upper portion of said lower press plate (7) of said press machine (22) through a plurality of base fastener (13) and said base plate (6) has a central cylindrical portion (19) with an electrode die (5) secured over said central cylindrical portion (19) through a plurality of die fastener (12) and said electrode die (5) has a central cavity (20) for holding the electrode material therein; and
said lower press plate (7) is connected to said drive system (27) configured to move said lower press plate (7) in up, down, forward and backward direction for flat and pin punching action on the electrode material placed on said electrode die (5).
2. The device to fabricate three dimensional electrode, as claimed in claim 1, wherein said drive system (27) includes but not limited to an electric motor, a hydraulic actuator, or a pneumatic actuator.
3. The device to fabricate three dimensional electrode, as claimed in claim 1, wherein said flat punch (17) is coupled to the lower central portion of said upper punch press plate (16) through a plurality of punch press plate fastener (18).
4. The device to fabricate three dimensional electrode, as claimed in claim 1, wherein the shape of said central cavity (20) is of any polygonal shape.
5. The device to fabricate three dimensional electrode, as claimed in claim 1, wherein the shape of said flat punch (17) is of any polygonal shape.
6. The device to fabricate three dimensional electrode, as claimed in claim 1, wherein said pin holder assembly (26) comprises an upper pin press plate (4) attached to said upper pin punch platform (25) of said press machine (22); a pin holder (1) is coupled to the lower central portion of said upper pin press plate (4); and a plurality of spring (15) is secured between said upper pin press plate (4) and an ejector plate (3) to facilitate spring back action of said ejector plate (3).
7. The device to fabricate three dimensional electrode, as claimed in claim 6, wherein said pin holder (1) is coupled to the lower central portion of said upper pin press plate (4) through a plurality of pin fastener (9) and a plurality bolts (10).
8. The device to fabricate three dimensional electrode, as claimed in claim 6, wherein said pin holder (1) comprises a pin punch (2) having an array of pins provided to punch an array of holes in the electrode material placed in said central cavity (20).
9. The device to fabricate three dimensional electrode, as claimed in claim 8, wherein the shape of the array of pin of said pin punch (2) is of any polygonal shape.
10. The device to fabricate three dimensional electrode, as claimed in claim 6, wherein said plurality of spring (15) is secured between said upper pin press plate (4) and said ejector plate (3) through a plurality of press plate fastener (8).
11. The device to fabricate three dimensional electrode, as claimed in claim 6, wherein said ejector plate (3) has a ejector plate cavity (21) provided to allow said pin punch (2) to pass through said ejector plate (3) and punch the holes in electrode material placed in said electrode die (5).
12. The device to fabricate three dimensional electrode, as claimed in claim 6, wherein said plurality of spring (15) is provided to separate said ejector plate (3) and said upper pin press plate (4) and provides spring back action after punching the array of holes in the electrode material placed in said electrode die (5).