Air Battery Porous Cathode Edge Design for Leakage Prevention

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Solution Overview

Problem

Typical air batteries face issues with electrolytic solution leakage and mechanical weakness of the porous cathode layer, which can be damaged by the current collector.

Innovation Solution

An air battery design featuring a porous cathode layer supported by an electrically conductive cathode support plate with a dense portion at the outer edge, preventing leakage and enhancing mechanical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a porous cathode layer with thin film thickness is used to enable electrolytic solution penetration, then electrochemical performance is improved, but mechanical strength deteriorates causing the cathode to be easily damaged by current collector pressure

Engineering Contradiction:

Improveelectrochemical performanceVSAvoidmechanical strength of cathode

Core Design Contradiction:

Use of energy by moving objectVSStrength

Solution Approach 1:

The cathode structure is designed with spatially varying properties: the central region maintains high porosity for electrolyte penetration and electrochemical activity, while the peripheral region develops a dense structure that provides mechanical reinforcement. This local differentiation allows the cathode to simultaneously achieve good electrochemical performance and mechanical strength without compromising either function.

Inventive Principle:

Principle #3Local quality

2Productivity

If a porous cathode layer is used to allow electrolytic solution flow, then electrochemical reaction efficiency is improved, but electrolytic solution leakage occurs from the cathode edges

Engineering Contradiction:

Improveelectrochemical reaction efficiencyVSAvoidelectrolytic solution leakage

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The cathode is designed with heterogeneous porosity distribution where the interior maintains high porosity for efficient electrolyte flow and electrochemical reactions, while the periphery forms a dense barrier structure that prevents electrolyte leakage. This local quality differentiation simultaneously achieves high productivity and eliminates harmful leakage.

Inventive Principle:

Principle #3Local quality

3Weight of moving object

If the cathode layer is made thinner to reduce battery weight, then weight is reduced, but the cathode becomes more susceptible to damage from current collector pressure

Engineering Contradiction:

Improvebattery weightVSAvoidcathode durability

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The cathode employs thickness and density variation: the central region remains thin for low weight while the peripheral region develops increased thickness and density to form a protective edge structure. This local quality differentiation allows the cathode to be lightweight overall while maintaining durability against current collector pressure.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10181625B2Air battery and air battery stack using same

Publication Date: 2019.01.15 NISSAN MOTOR CO LTD

AI summary

The present invention is an air battery B1 in which a cathode assembly 40, including a porous cathode layer 41, and an anode assembly 30 are disposed on mutually opposite sides of an electrolytic solution layer β. It includes an electrically conductive cathode support plate 42 that supports the porous cathode layer 41 and includes a ventilation area, wherein the porous cathode layer 41 covers the ventilation area and further extends to a non-ventilation area outside the ventilation area, and includes a dense portion 41a at an outer edge part facing the non-ventilation area.