3D Secondary Battery Electrode Structure for Fast Charging Density
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Solution Overview
Problem
Lithium batteries face limitations in achieving high energy density and rate capability, which are essential for advanced electronic devices, as existing designs do not effectively optimize the structure and manufacturing processes to enhance both energy storage and charging speed.
Innovation Solution
The proposed secondary battery design includes a unique structure with perpendicular active material layers, a solid electrolyte, and conductor layers that increase the reaction surface area and active material volume fraction, allowing for improved ion exchange and energy storage, along with a manufacturing method involving sheet stack structures and sacrificial layers to create a 3D electrode structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional battery structures are used, then manufacturing is simple, but energy density and rate capability are limited
Solution Approach 1:
The patent transitions from conventional 2D planar electrode structures to a 3D vertically stacked configuration. Multiple active material layers are arranged perpendicular to the substrate, creating a three-dimensional architecture that increases the volume of active material per unit area. This dimensional change enables higher energy density without proportionally increasing the device footprint, while the modular stacked design maintains manufacturing feasibility through layer-by-layer fabrication processes.
Solution Approach 2:
The patent implements a nested structure where conductor layers are inserted within and between active material layers. The conductor layers are positioned inside the vertical stacks of active material, creating a nested arrangement that provides multiple electron transport pathways through the active material. This nested conductor configuration enhances rate capability by reducing electron transport distances without requiring a complete restructuring of the battery architecture.
2Productivity
If conventional electrode structures are used, then manufacturing is straightforward, but charging speed is limited
Solution Approach 1:
The patent divides the electrode structure into multiple discrete active material layers separated by conductor layers. Instead of a single continuous electrode, the active material is segmented into multiple thin layers stacked vertically. This segmentation reduces the distance electrons and ions must travel through the active material, enabling faster charge rates. The segmented structure also allows better electrolyte penetration between layers, further enhancing charging speed.
Solution Approach 2:
The conductor layers serve as intermediary elements that facilitate rapid electron transport between the active material layers and the current collector. These intermediate conductor layers act as electron highways, reducing the overall electron transport resistance in the electrode. By introducing these intermediary conductor structures, the patent achieves faster charging speeds without requiring a complete redesign of the electrode architecture.
3Quantity of substance
If active material volume is increased, then energy density improves, but ion exchange efficiency decreases
Solution Approach 1:
The patent creates local variations in the electrode structure by alternating dense active material layers with conductor-rich separator layers. Each local region has optimized properties: active material layers provide high volumetric energy density, while the interspersed conductor layers provide efficient ion and electron transport pathways. This local quality differentiation allows the electrode to simultaneously achieve high active material volume fraction and fast ion exchange kinetics.
Solution Approach 2:
The conductor layers and the interfaces between active material layers create a porous or hierarchically structured architecture that facilitates electrolyte penetration. The vertical stacking creates interlayer spaces that allow electrolyte to reach deep into the electrode structure, maintaining fast ion exchange even as active material volume increases. This porous arrangement prevents the electrode from becoming a dense block that would hinder ion transport.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances both the energy density and rate capability of the battery, leading to increased charging speed and durability, making it suitable for small devices like mobile and wearable electronics while maintaining stability.
Implementation Method 1
an electrolyte layer disposed between the plurality of first active material layers and the plurality of second active material layers
Implementation Method 2
a first conductor layer that electrically contacts the first electrode collector layer and is inserted into the plurality of first active material layers
Data Source
AI summary
A secondary battery includes a first electrode collector layer and a second electrode collector layer, which face each other, a plurality of first active material layers that electrically contact the first electrode collector layer and are substantially perpendicular to the first electrode collector layer, a plurality of second active material layers that electrically contact the second electrode collector layer and are substantially perpendicular to the second electrode collector layer, and a first conductor layer that electrically contacts the first electrode collector layer and is inserted into the plurality of first active material layers.