3D Network Anode Particulates for Alkali Metal Batteries
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Solution Overview
Problem
Alkali metal batteries face challenges with low active material mass loading, leading to low volumetric capacity and energy density due to thin electrodes and poor packing density, which limits their performance in achieving high energy and power densities.
Innovation Solution
The development of an anode material composition in particulate form, comprising an anode active material, an electron-conducting material, and a lithium or sodium ion-conducting electrolyte, forming a 3D network of electron-conducting pathways and ion-conducting channels to enhance electron and ion transport without increasing electron transport resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional slurry coating procedure is used to manufacture electrodes, then manufacturing process is simple and easy to implement, but electrode thickness is limited to thin electrodes (100-200 μm) resulting in low active material mass loading
Solution Approach 1:
The invention segments the electrode structure into a three-dimensional network of conductive pathways and ion-conducting channels, dividing the electrode into functional units that can be densely packed. This segmentation allows thick electrodes to be constructed from modular components, enabling high active material mass loading while maintaining manufacturability through scalable assembly processes.
Solution Approach 2:
The invention transitions from conventional two-dimensional planar electrodes to three-dimensional structured electrodes with interconnected conductive pathways and ion-conducting channels. This dimensional change enables significantly increased active material mass loading by utilizing volumetric space efficiently, allowing electrodes to exceed the thickness limitations of conventional coating procedures.
2Quantity of substance
If electrode thickness is increased to improve active material mass loading, then volumetric capacity and energy density improve, but electron transport resistance increases and structural integrity deteriorates
Solution Approach 1:
The invention implements local quality by creating distinct regions with specialized functions: conductive pathways optimized for electron transport and ion-conducting channels optimized for ion transport. This local differentiation allows thick electrodes to maintain low electron transport resistance in conductive regions while providing structural support in framework regions, resolving the conflict between thickness and structural integrity.
Solution Approach 2:
The invention uses composite electrode structures combining conductive materials for electron transport and ion-conducting materials for ion transport, creating a multi-phase composite that simultaneously achieves high active material loading, low electron transport resistance, and maintained structural integrity through the synergistic combination of different material phases.
3Quantity of substance
If electrode thickness is increased to improve active material mass loading, then volumetric capacity improves, but electron transport resistance increases
Solution Approach 1:
The electrode is segmented into a three-dimensional network of conductive pathways that provide multiple parallel routes for electron transport. This segmentation reduces electron transport resistance by creating shorter effective transport paths and increasing the number of parallel conduction channels, allowing thick electrodes to maintain low resistance despite increased thickness.
Solution Approach 2:
The invention introduces three-dimensional conductive pathways that extend through the electrode thickness, transforming electron transport from a two-dimensional surface phenomenon to a three-dimensional volumetric process. This dimensional change enables efficient electron transport throughout thick electrodes by providing direct conduction routes from any point in the electrode to current collectors.
4Quantity of substance
If active material mass loading is increased to improve energy density, then battery capacity improves, but manufacturing complexity increases due to thicker electrodes requiring longer drying zones and more binder resin
Solution Approach 1:
The invention employs porous electrode structures with controlled porosity that accommodate high active material loading while maintaining adequate permeability for electrolyte penetration and ion transport. This porous architecture reduces the need for excessive binder resin to hold the structure together, simplifying manufacturing by eliminating the requirement for excessively long drying zones while still achieving high mass loading.
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 solution enables the creation of alkali metal batteries with high active material mass loading, high volumetric capacity, and high energy and power densities, addressing the limitations of conventional battery designs.
Implementation Method 1
the electron-conducting material forms a 3D network of electron-conducting pathways in electronic contact with the anode active material
Implementation Method 2
the electrolyte forms a 3D network of lithium ion- or sodium ion-conducting channels in ionic contact with the anode active material
Implementation Method 3
an anode active material capable of reversibly absorbing and desorbing lithium ions or sodium ions
Data Source
AI summary
Provided is an anode particulate, having a dimension from 10 nm to 100 μm, for use in an alkali metal battery, the particulate comprising (i) an anode active material capable of reversibly absorbing and desorbing lithium ions or sodium ions, (ii) an electron-conducting material, and (iii) a lithium ion-conducting or sodium ion-conducting electrolyte, wherein the electron-conducting material forms a three dimensional network of electron-conducting pathways in electronic contact with the anode active material and the electrolyte forms a three dimensional network of lithium ion- or sodium ion-conducting channels in ionic contact with the anode active material. The particulate can be of any shape, but preferably spherical or ellipsoidal in shape. Also provided is a cathode in a particulate form containing a cathode active material, an electron-conducting material forming a three dimensional network of electron-conducting pathways, and a lithium ion-conducting or sodium ion-conducting electrolyte forming a three dimensional network of ion-conducting channels.