3D Electrode Structure with Active Material-Metal Composite
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing secondary battery electrode structures face limitations in enhancing energy density, rate capability, and structural stability, particularly due to low electrical conductivity and differences in shrinkage rates between current collecting layers and active material plates.
Innovation Solution
The development of three-dimensional (3D) electrode structures incorporating a current collecting layer, active material plates with an active material-metal sintered composite, and a base layer with high electrical conductivity, along with partition walls to support the plates, which includes metals like Al, Cu, Ni, and Pd, and a glass material for enhanced bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a conventional current collecting layer and active material plate structure is used, then the battery structure is simple, but the energy density and rate capability are limited due to low electrical conductivity
Solution Approach 1:
The patent employs composite materials by integrating metal particles (such as aluminum, copper, nickel, or cobalt) into the active material plates and base layer to form an active material-metal composite. This composite structure enhances electrical conductivity within the active material itself, enabling improved rate capability and energy density without relying solely on the current collecting layer. The metal particles create conductive pathways throughout the active material matrix, resolving the contradiction between energy density and electrical conductivity.
Solution Approach 2:
The current collecting layer serves as an intermediary component that is optimized for electrical conductivity while the active material plates provide capacity. The patent enhances this intermediary role by adding metal particles to both the current collecting layer and active material plates, creating a multi-level conductive network. This intermediary approach allows the system to achieve high energy density through increased active material volume fraction while maintaining high electrical conductivity through the metal-enhanced conductive pathways.
2Use of energy by moving object
If the active material volume fraction is increased to improve energy density, then the capacity increases, but the structural stability deteriorates due to differential shrinkage between current collecting layer and active material
Solution Approach 1:
The patent applies local quality by incorporating metal particles specifically within the active material plates and base layer regions where shrinkage stress occurs during charging and discharging. These metal particles act as local reinforcement agents that counteract the differential shrinkage between the active material and current collecting layer. The local addition of metal particles provides structural support precisely where needed, enabling higher active material volume fractions while maintaining structural stability.
Solution Approach 2:
The active material-metal composite structure provides both the high capacity of active material and the structural stability of metal particles. The metal particles form a reinforcing network within the active material matrix, preventing structural degradation during cycling. This composite approach allows the patent to increase active material volume fraction for higher energy density while the metal framework maintains structural integrity despite differential shrinkage.
3Reliability
If metals are added to enhance electrical conductivity and structural stability, then the conductivity and strength improve, but the device complexity increases
Solution Approach 1:
The patent merges multiple functions into the active material-metal composite structure. The metal particles simultaneously provide electrical conductivity enhancement, structural reinforcement against shrinkage stress, and mechanical strength. This merging of functions into a single composite material system avoids the need for separate conductive additives and structural reinforcement layers, thereby limiting the increase in device complexity while achieving multiple performance improvements.
Solution Approach 2:
The metal particles in the active material-metal composite serve multiple functions: they act as conductive pathways for electron transport, provide structural reinforcement to counteract shrinkage stress, and enhance mechanical strength. This multi-functionality means that a single material modification (adding metal particles) achieves multiple performance goals simultaneously, avoiding the need for separate components and processes that would increase device complexity.
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
The 3D electrode structure significantly improves energy density, rate capability, and structural stability by increasing active material volume fraction and reaction area, while maintaining high electrical conductivity and mechanical strength.
Implementation Method 1
a base layer provided between the current collecting layer and the plurality of plates, the base layer including an active material-metal sintered composite
Implementation Method 2
the base layer including an active material-metal sintered composite
Data Source
AI summary
A three-dimensional (“3D”) electrode structure includes a current collecting layer, a plurality of plates protruding from the current collecting layer and including an active material, and a base layer provided between the current collecting layer and the plurality of plates. The base layer includes an active material-metal sintered composite. The plurality of plates includes an active material-metal sintered composite. A metal content of the active material-metal sintered composite of the plurality of plates is less than a metal content of the active material-metal sintered composite of the base layer. At least one partition wall supporting the plurality of plates is further provided on the base layer.