3D Porous Cathode Structure for Low-Resistance Solid-State Cells
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Solution Overview
Problem
Current solid-state lithium-ion batteries face challenges such as dendrite formation, low energy density, high internal resistance, and difficulty in achieving a hermetic seal due to brittle ceramic electrolytes and discontinuous contacts between layers, limiting their practical implementation and performance.
Innovation Solution
A 3D porous cathode structure with ionically and electronically conducting networks is integrated into a monolithic ceramic electrochemical cell housing, using multi-material additive processes to form a continuous electrolyte network and hermetically sealed anode spaces, enhancing lithium ion and electron transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic electrolyte is used to prevent dendrite formation and enable high voltage operation, then safety and energy density are improved, but the brittle nature of ceramic materials causes difficulty in achieving hermetic sealing and continuous contact between layers
Solution Approach 1:
The patent employs a porous ceramic electrolyte layer that maintains ionic conductivity while accommodating thermal expansion and mechanical stress. The porous structure allows for better interfacial contact between layers without requiring perfect hermetic sealing, thus resolving the contradiction between using brittle ceramic materials and achieving reliable assembly.
Solution Approach 2:
The patent uses composite structures combining ceramic electrolyte with other materials (such as buffer layers or flexible substrates) to compensate for the brittleness of pure ceramic. This composite approach maintains the dendrite-preventing properties of ceramic while improving manufacturability and sealing capability.
2Ease of manufacture
If conventional planar battery structure is used, then manufacturing is simpler, but discontinuous contact between layers results in high internal resistance and poor rate performance
Solution Approach 1:
The patent transitions from a conventional planar (2D) battery structure to a three-dimensional architecture where the ceramic electrolyte forms continuous pathways through the cell. This dimensional change enables continuous ionic conduction while maintaining manufacturing feasibility, thus resolving the contradiction between structural simplicity and low internal resistance.
3Quantity of substance
If lithium metal anode is used to achieve high energy density, then capacity is improved, but dendrite formation during charging causes short circuits and safety hazards
Solution Approach 1:
The patent introduces a ceramic electrolyte layer as an intermediary between the lithium metal anode and cathode. This ceramic barrier prevents direct contact and potential short circuits caused by dendrites, while still allowing ionic transport. The porous structure of the ceramic enables it to accommodate lithium deposition without compromising safety, thus resolving the contradiction between high energy density and safety.
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 achieves higher volumetric energy density, lower internal resistance, and improved rate performance by ensuring continuous ionic conductivity and hermetic sealing, reducing the risk of dendrite formation and enhancing battery capacity.
Implementation Method 1
a ceramic electrolyte separator, located between the cathode and the anode
Implementation Method 2
an electronically conducting network extending on sidewall surfaces of the pores from the cathode current collector to the electrolyte separator
Data Source
AI summary
An electrochemical cell is provided, which includes a cathode comprising a three dimensional (3D) porous cathode structure, an anode, an electrolyte separator, comprised of a ceramic material, located between the cathode and the anode, and a cathode current collector, wherein the cathode is located between the cathode current collector and the electrolyte separator. The 3D porous cathode structure includes ionically conducting electrolyte strands extending through the cathode from the cathode current collector to the electrolyte separator, pores extending through the cathode from the cathode current collector to the electrolyte separator, and an electronically conducting network extending on sidewall surfaces of the pores from the cathode current collector to the electrolyte separator.