What is the production rate for the metal and active electrode using the vacuum system with magnetrons (our technology)? What kind of productivity in sq. m. per year in comparison with existing technologies?
The production rate depends on the width of the foil to be sprayed. For example, for a foil width of 1,000 mm, a deposition rate of 1 m per minute and 6,000 work hours.
In this case the annual productivity (three shifts, 6,000 hours) will be:
6,000 x 60 = 360,000 minutes or 360,000 sq.m.
Standard technology productivity depends on foil size and the level of process automation. But production can be created with reference to the productivity required – it is only a matter of price…
Explain why increasing the useful life of the battery is important? What are the advantages for the seller?
The useful life of batteries of the same type is directly linked with the quality of its production. Failure to comply with technology and poor manufacturing quality increase the internal resistance of the battery, with its subsequent degradation, for example, by the active layer flaking off from the metal.
What is the advantage to the manufacturer? The fact that a buyer with some idea about their useful life at the same price would rather buy batteries with more charge cycles than a battery with a smaller number of cycles. In other words, sales of batteries with fewer charge cycles will continue to decline.
Is production of the current collector with a dense carbon layer by magnetron deposition a much more advanced version of the foil etching process?
Etching the foil increases the adhesion “sticking” of the active electrode, but does not reduce contact resistance. And for this reason the “serious” manufacturer uses etched aluminum foil. Therefore, usually, the active electrode flakes off from the copper foil but not from etched aluminum foil.
The magnetron method removes the oxide film, and replaces it with a dense carbon coating 80 nm thick improving the adhesion “sticking” of the active electrode to the current collector, and also reduces contact resistance between the current collector and the active electrode.
How much CHEAPER (or more expensive) is it to produce a current collector by magnetron deposition than by chemical etching?
Foil and current collector market price
Income distribution and cost for the sale of 1kg of carbon coated foil (= collector) produced by magnetron deposition:
The current collector market is not only supercapacitors, but also electrolytic capacitors and lithium-ion batteries, i.e. much wider.
What will the use of magnetron technology give the manufacturer? Will their products be more expensive (or even cheaper)? What specific benefits will the manufacturer be able to describe on the labeling of their batteries to increase the demand for their products? What will the use of magnetron technology give consumers of the batteries?
The diagram shows the cost distribution for manufacturing the battery. The cost of the battery is reduced by automating the process of materials generation.
For the manufacturer the new magnetron technology will:
• Improve the reliability and repeatability of the materials generation process
• Reduce direct labor costs.
• Reduce the cost of cathode and anode materials.
• Increase the energy potential of the active electrode.
It increases capacity of the energy storage device at the same cost, which in turn will allow the manufacturer to increase sales.
About the label. You can put manufactured using nanotechnology… on the label…
You say that "The existing technologies have reached their "ceiling” and, if you do not change the production technology, it is impossible to reduce the cost of energy storage". Explain how your magnetron technology can reduce the cost of energy storage?
An analysis of patents aimed at generating new materials reveals the following trend. 89% of patents are devoted to the creation of new chemical formulations for the anode and cathode. Technology design engineers want to increase the energy component of the active electrode. The aim is to increase the specific energy to 400 Wh/kg. The magnetron makes it possible to create preassigned mix formulations for the anode and cathode materials. To get this result using the standard technology for mixing chemicals is impossible.
From the picture it is clear that no-one is thinking about the current collector. Everyone thinks that everything is fine with the current collector. In this sense there are openings for us.
By how much can charge speed be increased (approximately at least) by using YOUR technological process WITHOUT adversely affecting battery life?
For the supercapacitor the charge speed is not a big deal. But it has low specific energy – to 50 Wh/kg. Increasing the charge speed is possible for electronic technology, there is enough for about 5 Wh/kg (Nokia BL-5B has a capacity = 3.2… 4.1 Wh/kg).