3D Anode Current Collector for Lithium Metal Batteries

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Solution Overview

Problem

Lithium metal batteries face issues with non-uniform lithium deposition leading to dendrite formation, which causes battery deterioration and short-circuiting due to the inability of existing host current collector designs to fully restrict dendrite growth.

Innovation Solution

An anode current collector host structure with a multi-material design featuring a conductive layer and a non-conductive layer, including recesses that increase the surface area for lithium deposition while preventing dendrite growth, comprising a conductive layer of metal and a non-conductive layer with recesses that are partially filled by the electrolyte, where the opening width is between 20% and 70% of the recess width.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If lithium is continuously deposited during battery operation, then the battery can function and provide energy storage, but non-uniform deposition occurs leading to dendrite formation and battery deterioration

Engineering Contradiction:

Improvebattery cycle lifeVSAvoidbattery safety

Core Design Contradiction:

Duration of action of moving objectVSReliability

Solution Approach 1:

The current collector host structure is segmented into multiple recesses (e.g., holes or grooves) that divide the deposition area into discrete zones. This segmentation prevents continuous unidirectional dendrite growth by providing multiple nucleation sites and distributing lithium deposition across separated regions, thereby extending battery cycle life while maintaining safety.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The current collector host structure acts as an intermediary between the electrolyte and the anode, providing a controlled interface for lithium deposition. The recesses in the host structure mediate the deposition process by guiding lithium ion flow and enforcing uniform deposition patterns, preventing direct harmful interactions between lithium and the bulk current collector that would lead to dendrite formation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If existing host current collector designs are used, then the battery structure is simple, but they fail to fully restrict dendrite growth causing short-circuiting

Engineering Contradiction:

Improvedendrite growth restrictionVSAvoidcurrent collector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The current collector host structure incorporates a porous or hollow configuration with recesses that provide internal volume for lithium deposition. This porous architecture increases the effective surface area for uniform lithium accommodation while maintaining structural integrity, effectively restricting dendrite growth without requiring excessively complex external designs.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention transitions from a conventional flat two-dimensional current collector to a three-dimensional structure with recesses extending into the current collector thickness. This dimensional change provides additional deposition space within the bulk structure, enabling uniform lithium accommodation and dendrite restriction while keeping the overall device footprint compact.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Manufacturing precision

If lithium deposits on a non-uniform surface, then deposition continues, but the non-uniform surface exasperates further non-uniform deposition leading to accelerated dendrite formation

Engineering Contradiction:

Improvelithium deposition uniformityVSAvoidbattery operational lifespan

Core Design Contradiction:

Manufacturing precisionVSDuration of action of stationary object

Solution Approach 1:

The current collector host structure is pre-formed with recesses and uniform surface features before lithium deposition begins. This preliminary structuring creates predetermined uniform deposition sites that guide lithium ion distribution from the first cycle, preventing the development of non-uniform surfaces that would otherwise accelerate dendrite formation and extend battery operational lifespan.

Inventive Principle:

Principle #10Preliminary action

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 proposed solution enhances the cycle life and quick chargeability of lithium metal batteries by reducing dendrite growth and ensuring uniform lithium deposition within the host structure, thereby preventing battery deterioration.

Implementation Method 1

recesses formed through the non-conductive layer and into the conductive layer, each recess having an opening in the non-conductive layer with a width that is smaller than a largest width of the recess, wherein the electrolyte at least partially fills the recesses

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS11444285B2Three-dimensional anode current collector for lithium batteries

Publication Date: 2022.09.13 NISSAN MOTOR CO LTD

AI summary

A lithium metal battery has a cathode current collector, a cathode active material layer, an electrolyte, and an anode current collector host structure interfacing with the electrolyte. The anode current collector host structure comprises a conductive layer, a non-conductive layer on the conductive layer, and recesses formed through the non-conductive layer and into the conductive layer, each recess having an opening in the non-conductive layer with a width that is smaller than a largest width of the recess.