Description:DETAILED DESCRIPTION OF THE INVENTION
The EES devices fabricating system (600) for the fabrication of EES device incorporates a a designing system (601), a tessellation system (602), an infill system (603), a slicing system (604), a path system (605), and a fabrication system (606), to fabricate the EES device (101) with designed shape and process variables.
The method for fabricating EES device with Plast-Ex fabricator (200) includes a solid shape of electrodes which incorporates cathode (102), anode (104), and separator (103) of the desired shape and size, designed utilizing the designing system (601). Converting the electrode design model (301) to tessellated electrode design model (302) utilizing the tessellation system (602). Selecting the infill pattern and density for tessellated electrode design model (302) utilizing the infill system (603). Converting the infilled electrode design model (303) into multiple layers utilizing the slicing system (604). Creating the path instructed model (305) with path instruction for filaments deposition from the sliced model (304) utilizing the path system (605). Fed the abovementioned path instruction to the fabrication system (606). Feeding of cathode filament (201), anode filament (202), and separator filament (203) to the multi-filament extruder assembly (204) of the fabrication system (606). The multi-filament extruder assembly (204) squeezes out the electrode material layer on the heated printing surface (212) and then forms succeeding layers on top of previous one another until the EES device (101) is wholly constructed.
The designing system (601) is a computer assisted design system to design the various shapes for electrodes such as cathode (102), anode (104), and separator (103). It provides a wide variety of tools and functions, such as the ability to create geometric forms, add measurements and notes, and control the location and direction of electrodes in the design, for the purpose of creating the 3D designs. Advanced features like models, animations, and analysis tools are also available to allow designers and engineers to try and improve their ideas before they are constructed. It is an effective tool for designers and engineers, as it offers many features for developing and perfecting designs that can boost productivity, precision, and quality for EES device (101).
The tessellation system (602) provides a method for completely covering a surface with a pattern of triangular forms that repeats itself without any empty spaces. The tessellated electrode design model (302) is a collection of triangles so that it may be produced more quickly. The tessellation system (602) can be utilized in many fields, including construction, design, and the visual arts.
The infill system (603) uses a predetermined pattern fill inside of a solid electrode. Since infill provides structural support for the item being fabricated and decreases fabrication time and material usage, it is an integral element of Plast-Ex fabricator (200). The final electrode's strength, weight, and adaptability is improved by tailoring the infill pattern and its density. Honeycomb infill pattern (401), wiggle infill pattern (402), triangular infill pattern (403), grid infill pattern (404), and rectilinear infill pattern (405) are all rather frequent. Stronger and longer-lasting fabrications cost more effort and material, but the payoff is worth it. Making electrode of EES device (101) that can endure mechanical stress requires the use of infill system (603) for Plast-Ex fabricator (200). The infill pattern used for electrodes may be altered to meet the requirements of the EES device (101) in terms of stiffness, weight, charge storage capacity, and temperature resistance. The overall strength, longevity, and functioning of the electrodes is greatly dependent on the infill used throughout the fabrication process.
The honeycomb infill pattern (401) is a structural configuration employed in the realm of Plast-Ex fabricator (200) for the purpose of occupying the voids present within a fabricated electrode (215). The inspiration for this pattern is derived from the inherent structure of honeycomb cells, which exhibit a hexagonal shape and are arranged in a contiguous pattern of adjacent cells. The honeycomb configuration is renowned for its robustness, resilience, and low mass, rendering it a prime selection for populating the inner regions of fabricated electrode (215). The honeycomb infill pattern (401) is generated in Plast-Ex fabricator (200) through the incorporation of a layer of hexagonal cells in the interior of the fabricated electrode (215). The cells exhibit interconnectivity, resulting in a consistent configuration that imparts robustness and stiffness to the fabricated electrode (215), while simultaneously economising on resources and expediting the fabricating process. The customization of the honeycomb infill pattern (401) is achievable through the manipulation of the cell size and wall thickness. The utilisation of variable parameters in the Plast-Ex fabricator (200) enables the creation of parts with varying degrees of strength and weight. The utilisation of honeycomb infill pattern (401) in Plast-Ex fabricator (200) is a multifaceted and effective approach to filling the internal structure of fabricated electrode (215), resulting in enhanced robustness, longevity, and decreased mass, while simultaneously reducing material consumption and fabrication time.
For wiggle infill pattern (402) in Plast-Ex fabricator (200), the material is deposited in a sequence of wavy and zigzagging lines that cross over each other to fill the internal structure of the electrode shape. The wiggle infill pattern (402) can be used to make electrodes in the way the intersecting lines affect the structure. The wiggle infill pattern (402) can also be used to make compressible and cushioned electrodes for EES device (101), which can serve as shock absorbers. It has the advantage of producing rapidly due to the ability of multi-filament extruder assembly to move back and forth, making it more efficient. It is a good choice for producing flexible, elastic, compressible, and cushioned electrodes in a fast and easy way.
The triangular infill pattern (403) is generated through the process of depositing the filament material in a sequence of interconnected triangles, thereby producing a recurring design of interlocking shapes, as the nomenclature implies. The utilisation of this pattern is a prevalent practise in Plast-Ex fabricator (200) due to its ability to confer substantial strength and rigidity to the fabricated electrodes (215), while simultaneously reducing the consumption of material. The lattice structure formed by the interlocking triangles exhibits a high degree of strength and uniform distribution of weight and stress, thereby imparting significant resistance to bending and fracturing of the fabricated electrodes (215). This pattern can be customized by adjusting the size and spacing of the triangles. The capability of the Plast-Ex fabricator (200) to produce objects with varying degrees of strength and weight is contingent upon the intended use case. Increasing the size of a triangle will result in a stronger structure, however, this will also lead to a higher consumption of material and a longer fabrication time. The implementation of a triangular infill pattern (403) is a practical approach for fabricated electrodes (215) that necessitate a considerable level of durability and stiffness, such as structural elements.
The grid infill pattern (404) is used to fill in the gaps between the produced layers, while depositing the material in a succession of perpendicular lines to make the pattern; the lines run in opposite directions from one another. Because it strikes a nice equilibrium between strength and material utilization for Plast-Ex fabricator (200). The powerful lattice structure formed by the grid's perpendicular lines makes the item resistant to twisting and fracturing because the load is spread out across a larger area. The spaces between the lines also facilitate effective use of material, which in turn shortens the fabrication process and lowers its associated costs. The quantity of material used, and the structure's strength can be modified by altering the line spacing of the grid infill pattern (404). It will require more time and more material to print at a tighter spacing, but the result is a stronger construction. The grid infill pattern (404) is a flexible and economical method for filling the interior of fabricated electrodes (215), offering a decent compromise between strength and material utilisation. It's widely used because of the ease with which durable, lightweight constructions can be fabricated using Plast-Ex fabricator (200).
The rectangular infill pattern (405) is used in Plast-Ex fabricator (200) while providing the equilibrium between durability, adaptability, and material efficiency. The overlapping lines of the rectilinear infill pattern (405) produce a powerful lattice structure that disperses load and tension uniformly across the electrode, making it more resilient to deformation. However, the spaces between the lines allow for some elasticity and movement. The rectilinear infill pattern (405) can be altered by changing the line spacing and fabricating orientation. Because of this, the Plast-Ex fabricator (200) can produce things with varying degrees of rigidity and deformability. Smaller gaps, for instance, could result in a more robust structure, but would require more resources and more fabricating time. Rectilinear infill pattern (405) is ideal for mechanical components that need a middle ground between rigidity and deformability with lightweight construction.
Using Plast-Ex fabricator (200), the quantity of material used to cover the interior of a fabricated electrode (215) is referred to as the infill density and it can be altered, which is usually stated as a proportion of the electrode's overall volume and weight. More material is used to cover the fabricated electrodes (215), making it sturdier and more rigid, if a greater infill density is used. However, fabrication at a greater infill density takes more time and costs more in materials. However, a lighter and less rigid construction is the outcome of a lower infill density because less material is used. However, fabricated electrodes (215) with lower infill concentrations may be more easily bent. Material used for the infill structure is determined by the infill density, which is often adjusted between 1% and 100% like 10% (501), 20% (502), 30% (503), 40% (504), 50% (505), 60% (506), 70% (507), 80% (508), 90% (509) and 100% (510) to get the required qualities in the fabricated electrodes (215).
The optimum infill density for a fabricated electrodes will be different for each use case and set of desired characteristics. For instance, a greater infill density may be necessary for electrodes that will be under a lot of stress, while a lower infill density may be necessary for electrodes that are intended to be lightweight in order to conserve resources. The infill system (603) allows users to customise the filling depth to meet their individual requirements. The sturdiness, weight, and general quality of a fabricated electrode (215) can be greatly affected by the infill density used.
The slicing system (604) is used to slice the infilled electrode design model (303) based on the desired layer thickness. The slicing system (604) gives the user control over the layer thickness or the number of layers. The quantity of layers needed to construct an electrode determines the fabricating speed and time. More time will be required to produce an electrode with a low layer thickness.
The path system (605) is utilised to create toolpaths for the multi-filament extruder assembly (204) of Plast-Ex fabricator (200) for material deposition. The multi-filament extruder assembly (204) is programmed to follow a set of information generated based on the infill pattern, infill density and layer thickness. These instructions specify the route that the multi-filament extruder assembly (204) should take to produce the electrode design model (301). The path system (605) generates the path instruction that is both efficient and precise by considering the size and form of the multi-filament extruder assembly (204) in addition to the fabrication speed of the Plast-Ex fabricator (200). The path instructions are transferred to Plast-Ex fabricator (200) using a memory card.
The fabrication system (606), a Plast-Ex fabricator (200), which is a cartesian coordinate-based equipment with a hot extrusion mechanism for feeding cathode filament (201), anode filament (202) and separator filament (203). The X-axis, Y-axis and Z-axis motion mechanism are crucial parts of the proposed design. Combinedly, the X-axis, Y-axis and Z-axis motion mechanism mounted on a support frame (214) and produce the fabricated electrodes (215). A Plast-Ex fabricator (200) can produce electrodes from a path instructed model (305) by adding successive layers of material.
The Plast-Ex fabricator (200) includes the following subparts for fabrication of EES device (101):
Filaments: Filaments for Plast-Ex fabricator (200) are thermoplastics, that melt rather when heated, form easily into desired shapes, then harden once again when cooled. To construct the electrodes of EES device (101) item, three filaments namely cathode filament (201), anode filament (202), and separator filament (203) are fed into the multi-filament extruder assembly (204), where it is heated to its melting point and then squirted via a metal nozzle (205) while the multi-filament extruder assembly (204) travels along a route determined by the path system (605).
Multi-Filament Extruder Assembly: The Plast-Ex fabricator (200) has multi-filament extruder assembly (204) with ability to heat and feed three filaments into a metal nozzle (205). Using a multi-filament extruder assembly (204), it is possible to make cathode (102), separator (103), and anode (104) simultaneously to fabricate the EES device (101). The multi-filament extruder assembly (204) is the component of the Plast-Ex fabricator (200) responsible for feeding, heating, and extruding semi-liquid filament material into the electrode volume, where it is deposited in consecutive layers.
Guide rail: Two guide rail namely left guide rail (310) and right guide rail (206) is used to direct and assist the vertical travel of heated printing surface (312). It also facilitates synchronisation and damage-free operation.
Control knob: A control knob (207) is a mechanical component used to control the Plast-Ex fabricator (200) for fabrication of the designed electrodes. It is circular in form and used to choose the path instruction file to fabricate and provide limited manual control during fabrication.
Parameter display: A parameter display (208) is a piece of equipment that relays the present number of variables. It shows path instruction file chosen for fabrication and its process variables. It helps to check the process completion, position of heated printing surface (212) and metal nozzle (205).
Card reader: A card reader (209) is an electrical tool for reading and retrieving information from various cards. These cards contain path instruction file to fabricate which shows on parameter display (208) and selected using control knob (207).
Heated printing surface: It supports the fabricated electrodes (215) during fabrication. The adhesion and quality of the fabricated electrodes (215) can be enhanced with the assistance of the heated printing surface (212). The heated printing surface (212) is a flat surface heated to a specified temperature, generally between 20°C and 120°C. It is supported using a metal structure (211) for sustaining the weight of heated printing surface (212) and fabricated electrodes (215).
Feed screw: Linear motion is achieved by rotating a threaded rod inside a nut, with the threads of both the rod and the nut engaging. The heated printing surface (212) is motioned using the feed screw (213) in upward and downward direction while having the support and guide from the left guide rail (210) and right guide rail (206).
An EES device (101) consists of three components a cathode (102), an anode (104), and a separator (103). The cathode (102) is the electrode of an EES device (101) where the reduction reaction takes place. The fabrication of the cathode (102) requires the use of the cathode filament (201), which consists of lithium magnesium oxide at a weight of 12%, multi-walled carbon nano tubes at 23%, and poly-lactic acid at a weight of 65%. When an EES device (101) is being discharged, or utilized, the cathode (102) is where electrons mix with positively charged lithium ions to generate neutral atoms. An external device can be powered by the energy released during this procedure. When the EES device (101) is being charged, the lithium ions are freed from the cathode (102) and go back to the anode (104), switching roles and becoming the site of oxidation. As the location of the chemical interactions that allow the EES device (101) to store and release energy, the cathode (102) plays an essential role in the operation of the EES device (101) as a whole.
The anode (104) of an EES device (101) refers to the electrode that attracts negative ions and facilitates the occurrence of the oxidation reaction. The anode (104) is fabricated using the anode filament (202), which has 15% lithium titanium oxide, 35% graphene, and 20% poly-lactic acid by weight. In the context of a lithium-ion battery, it is common for the anode (104) to be composed of carbon. This anode (104) has the ability to intercalate lithium ions between its layers while the EES device (101) is being charged and subsequently deintercalated them during discharge. This process results in the release of electrons into the external circuit. The performance of EES device (101) can be significantly influenced by its properties, including the materials employed and the reactions taking place.
The EES device (101) has a separator (103) is a slender substance that is interposed between the cathode (102) and anode (104) in an EES device (101) to impede direct contact between them while simultaneously facilitating the movement of ions and electrons between the electrodes. The separator (103) plays a crucial role in the functioning of an EES device (101) by mitigating the risk of short circuits and other potential safety hazards that may result from direct contact between the cathode (102) and anode (104). The separator (103) is composed of a porous structure of poly-lactic acid, which exhibits chemical inertness and thermal stability. The separator's pores facilitate the permeation of the ions while simultaneously impeding the electrodes from contacting each other. The thickness of the separator (103) is subject to variation depending on the particular design and application of EES device (101). However, it is commonly observed to fall within the range of 10-20µm.
Apart from its function in averting short circuits, the separator (103) also serves as a regulator of the performance of EES device (101). The characteristics of the separator (103), including its surface area and pore size, have the potential to impact both the ion transport rate and EES device (101) capacity. A reduced pore size can lead to a decreased ion transport rate while potentially enhancing the stability and safety of the EES device (101). The separator (103) of the EES device (101) is an essential constituent while playing a crucial role in maintaining safe and dependable functioning by impeding direct interaction between the fabricated cathode (102) and anode (104) with controlling the performance. , Claims:We claim:
1. A customized shaped and sized electrochemical energy storage (EES) devices fabricating system (600), comprising:
a designing system (601),
a tessellation system (602),
an infill system (603),
a slicing system (604),
a path system (605),
a fabrication system (606),
wherein EES device (101) is consist of three parts a cathode (102), an anode (104), and a separator (103).
2. The designing system (601), as claimed in claim 1, designed the shapes and sizes of electrodes for EES device (101).
3. The tessellation system (602), as claimed in claim 1, simplified the complicated shape into an assemblage of triangles.
4. The infill system (603), as claimed in claim 1, has variation of infill pattern with its density.
5. The slicing system (604), as claimed in claim 1, distributed the designed parts into multiple layers of the customized EES device (101).
6. The path system (605), as claimed in claim 1, created the deposition path based on the designed shape and size of EES device (101).
7. The fabrication system (606), as claimed in claim 1, consists of three filaments which are feed utilizing a feeding mechanism through a multi-filament extruder assembly (204), and extruding it to the heated printing surface (212) based on the path instructions.
8. The EES devices fabricating system (600), as claimed in claim 1, provides the improvement to gravimetric and volumetric capacity for the customized shaped and sized EES devices (101) with applications as a structural component.