Air Electrode With Constricted Through Holes for Metal-Air Battery

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Solution Overview

Problem

Conventional metal-air batteries face issues with electrolytic solution leakage and detachment of the water repellent membrane from the catalyst layer, leading to reduced battery performance and safety concerns due to the collection of electrolyte between the membrane and catalyst layer, which inhibits air supply and reduces battery lifetime.

Innovation Solution

An air electrode configuration with a catalyst layer having through holes with a constriction, allowing the electrolytic solution to return to the current collector, preventing its collection between the water repellent membrane and the catalyst layer, and enhancing air permeability to maintain the electrode reaction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If through holes are formed in the catalyst layer to enhance gas permeability, then air supply to the catalyst layer is improved, but electrolytic solution may leak through the through holes

Engineering Contradiction:

Improvegas permeabilityVSAvoidelectrolytic solution leakage

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The catalyst layer is designed with a porous structure containing through holes that allow gas permeability while the water repellent membrane prevents electrolyte leakage through these same holes, creating a selective permeability system

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

Different regions of the catalyst layer have different properties: the through holes provide gas pathways while the water repellent membrane specifically treats the outer surface to repel electrolyte, creating localized functional zones

Inventive Principle:

Principle #3Local quality

2Reliability

If a water repellent membrane is provided outside the catalyst layer to suppress electrolytic solution leakage, then electrolyte leakage is reduced, but electrolytic solution may be collected between the membrane and catalyst layer causing detachment

Engineering Contradiction:

Improveelectrolytic solution leakage suppressionVSAvoidmembrane-catalyst layer bonding

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The harmful accumulation of electrolytic solution between the membrane and catalyst layer is prevented by extracting excess electrolyte through the through holes in the catalyst layer, which serve as drainage pathways

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The through holes act as an intermediary structure that allows controlled passage of substances: they permit gas transport while preventing electrolyte accumulation that would cause membrane detachment

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the catalyst layer structure allows electrolytic solution permeation, then ionic conduction is maintained, but battery lifetime is reduced due to leakage and performance deterioration

Engineering Contradiction:

Improvebattery lifetimeVSAvoidelectrolytic solution leakage

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

A water repellent membrane in the form of a thin film is applied to the outer surface of the catalyst layer, providing a flexible barrier that prevents electrolyte leakage while maintaining the porous structure for ionic conduction

Inventive Principle:

Principle #30Flexible shells and thin films

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 configuration effectively prevents electrolyte leakage and enhances battery performance by ensuring continuous air supply to the catalyst layer, improving reliability and safety while prolonging battery lifetime.

Implementation Method 1

a water repellent membrane... The water repellent membrane makes it possible to briefly suppress the leakage of an electrolytic solution

Methodology Applied

Scientific EffectWater repellency: Hydrophobe

Implementation Method 2

a plurality of through holes, through which the first face and the second face communicate with each other... the gas permeability enhanced by the through holes

Methodology Applied

Scientific EffectGas permeability: Permeation

Implementation Method 3

The plurality of through holes each have a constriction with an inner diameter smaller than either of an opening diameter in the first face and an opening diameter in the second face

Methodology Applied

Scientific EffectCapillary pressure: Capillary Pressure

Data Source

PatentUS11322786B2Air electrode, metal-air battery, and air electrode production method

Publication Date: 2022.05.03 SHARP KK

AI summary

An air electrode includes a current collector, a catalyst layer, and a water repellent membrane provided in this order. The catalyst layer has a first face in contact with either one of the current collector and the water repellent membrane, a second face in contact with either other of the current collector or the water repellent membrane, and a plurality of through holes, through which the first face and the second face communicate with each other. The through holes each have a constriction with an inner diameter smaller than either of an opening diameter in the first face and an opening diameter in the second face.