This proposal is for SOLID STATE storage which has already been successfully prototyped, incorporating several different chemistries. Although this manufacturing technique can be used with many battery and capacitor combinations and chemistries the inventors have mostly executed akaline combinations thus far. Plastic injection molding is the manufacturing platform. It is a well established high speed manufacturing method, capable of producing finished products in seconds. This version is a logical evolution of that. Except, rather than ONE resin in One mold, we are pushing the over mold / 2 shot technique a little bit further. Shuttle, spin stack, rotary molds and molding machines with multiple barrels for each material layer. 4-6 shots vs 1 -2. A completed 2,000 cell pack could be molded in the 5 minute range, depending on the thermoplastic binder resin set up / cure time. Fusing and blending one layer into the next, for better physical structure and superior intimate contact performance results. No dendrite degradation. It eliminates the metal cases and trays, so it is somewhat similar to lead acid, which also significantly reduces weight. There are patents issued and pending in the USA, China, India, Europe. So far, none of the recipes have been flammable or explosive. This has required years of experimentation and effort by industry veterans to figure out how to get the right results and find “The Sweet Spot”. Essentially certain geometric shapes and larger particle sizes of the “actives,” in thicker cross sections with 50%+ active ingredient loadings did the trick. This is not a “micro, nano, mini” conversation at this point.
Further because plastic injection molding can easily produce “finished parts,” a lot of sophisticated geometric shapes are possible, aka “conformal”. Also we do not need steel cylinder casings or flat cell cases and metal trays etc, we can save a lot of weight. Further, in the storage packs, we can use the wall section of the proximate cell instead of individual wall sections for each cell. So we have half as many wall sections, made of lighter weight materials. We can mold in the wiring buss, in a variety of different ways, thus eliminating the assembly labor for building up the stack/battery pack. We have witnessed that a cell that is cut in half or otherwise punctured or damaged, still functions, unlike current commercial offerings. This is faster, cheaper than anything today and we hope it can match and surpass the current product offerings in terms of field performance ( Kw hrs / cycle life). We believe that probably 20%+ of the estimated 50,000+ injection molding facilities in world today could make the modifications to their equipment and be in production in months.
The long time obstacle of higher costs for SOLID STATE is now history. Please go to JAKERTECHUSA.COM for more info. The next challenge is “performance.” Recyclability is done using thermal or chemical separation.