3D Electrode Super Lattice for Battery Capacity

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing electrochemical devices, such as lithium secondary batteries, face challenges in achieving high capacity, high output, and high energy density due to limitations in electrode design, including insufficient electron and ion conductivity of active materials, excessive use of conductive materials, and the weight and volume occupied by metal current collectors.

Innovation Solution

An electrode with a three-dimensional structure is developed, comprising a porous nonwoven web of polymer fibers with an active material composite and a second conductive material, forming a super lattice structure to minimize additives and enhance electroconductivity, using a light material current collector and optimizing porosity for improved ion transport and mechanical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metal current collector is used, then the electrode has good mechanical strength and electrical conductivity, but the electrode weight and volume increase, reducing capacity per unit weight or volume

Engineering Contradiction:

Improvemechanical strengthVSAvoidelectrode weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent removes the metal current collector from the electrode structure entirely, extracting this heavy component while maintaining electrode functionality through the self-supported three-dimensional network of active material particles connected by conductive materials

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The electrode is segmented into discrete active material particles (1-50 μm diameter) that form a three-dimensional network, replacing the continuous metal current collector structure with a distributed particle-based architecture that eliminates the need for heavy metal support

Inventive Principle:

Principle #1Segmentation

2Quantity of substance

If the active material has high theoretical capacity, then the energy density can be improved, but the electron and ion conductivity remains insufficient

Engineering Contradiction:

ImprovecapacityVSAvoidconductivity

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent creates a composite structure where active material particles are interconnected by conductive materials (carbon nanotubes, graphene, or conductive polymers), forming a composite network that combines the high capacity of active materials with the excellent conductivity of carbon-based materials

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The conductive materials are selectively positioned at the interfaces between active material particles and within the three-dimensional network, providing localized conductivity enhancement exactly where electron and ion transport is needed, without diluting the overall active material content

Inventive Principle:

Principle #3Local quality

3Reliability

If an excessive amount of conductive material is used to overcome low conductivity, then the conductivity is improved, but the energy density deteriorates

Engineering Contradiction:

ImproveconductivityVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent uses conductive materials in optimized partial amounts (1-50 parts by weight relative to 100 parts active material), providing sufficient conductivity through the three-dimensional network structure without excessive addition that would reduce energy density, achieving the right balance through controlled dosing

Inventive Principle:

Principle #16Partial or excessive action

4Quantity of substance

If additives such as conductive material and binder are minimized, then the energy density is improved, but the electroconductive network uniformity may deteriorate

Engineering Contradiction:

Improveenergy densityVSAvoidelectroconductive network uniformity

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The patent transitions from a two-dimensional planar electrode structure to a three-dimensional network architecture, where active material particles are arranged in three-dimensional space and interconnected by conductive materials, creating uniform electroconductive pathways in multiple directions and eliminating the need for excessive additives

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP3651239B1Electrode having three dimensional structure and electrochemical device including the same

Publication Date: 2023.07.05 LG ENERGY SOLUTION LTD

Figure 1a~1c
Figure 2~3
Figure 4~5

AI summary

Disclosed are an electrode having a three-dimensional structure, the electrode including: a porous nonwoven web including a plurality of polymer fibers that form an interconnected porous network; an active material composite positioned among the polymer fibers and including active material particles and a first conductive material; and a second conductive material positioned on an outer surface of the active material composite, wherein the interconnected porous network is filled homogeneously with the active material composite and the second conductive material to form a super lattice structure, and an electrochemical device including the electrode having a three-dimensional structure.