Battery Electrode Structure with Conformal Particle Engagement

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Solution Overview

Problem

Conventional battery electrode structures face challenges in achieving high granule compaction of cathode active materials, leading to reduced battery capacity and inefficient charge transfer due to the use of adhesives in the coating process.

Innovation Solution

A battery electrode structure is fabricated using a substrate with a conductive layer and active particles, where the active particles are sintered or melted to conformally engage with the conductive layer, forming a patterned structure that increases particle density and reduces adhesive usage, allowing for improved particle engagement and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesive is mixed with cathode active material to form the electrode, then the electrode can be formed by conventional coating technology, but the charge transfer efficiency is deteriorated

Engineering Contradiction:

Improveease of manufactureVSAvoidcharge transfer efficiency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent removes the adhesive component from the electrode structure entirely. The active particles are directly coated on the conductive board without any adhesive mixture, eliminating the harmful effect of adhesive on charge transfer efficiency while maintaining structural integrity through direct particle-to-conductor contact.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (adhesive) with a physical/structural bonding mechanism. Active particles are directly attached to the conductive board surface through methods such as sintering, melting, or direct deposition, substituting the chemical adhesive system with a mechanical/physical attachment system that preserves electrical conductivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Quantity of substance

If the thickness of cathode active material is increased to improve battery capacity, then more active material is available, but charge transfer efficiency is deteriorated by adhesive mixing

Engineering Contradiction:

Improvebattery capacityVSAvoidcharge transfer efficiency

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

By removing the adhesive from the system, the patent enables increased thickness of active material layers without the detrimental effect of adhesive interference. Thicker layers of active particles can be deposited directly on the conductive board, increasing battery capacity while maintaining efficient charge transfer pathways throughout the thicker structure.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If conventional paste preparation and coating technology is used, then the electrode can be manufactured easily, but granule compaction is insufficient leading to reduced battery capacity

Engineering Contradiction:

Improveease of manufactureVSAvoidbattery capacity

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent replaces the paste preparation and coating method with a direct particle deposition method. Instead of using paste that requires drying and bonding, active particles are directly coated onto the conductive board and then sintered or melted to achieve high granule compaction. This substitution of the manufacturing mechanism achieves both ease of manufacture and high battery capacity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and bonding parameters of the active particles. By applying sintering or melting processes, the particles transition from loose granules to a densely compacted structure with strong inter-particle bonding, significantly increasing granule compaction and battery capacity while maintaining manufacturing feasibility.

Inventive Principle:

Principle #35Parameter changes

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 method enhances battery capacity by 20% to 40% and extends battery life by ensuring tight engagement of active particles with the conductive layer, maintaining charge transfer efficiency even with increased thickness.

Implementation Method 1

a plurality of active particles disposed on a surface of the first conductive layer are sintered/melted so as to make each of the active particles having a first portion conformally engaged with the surface of the first conductive layer

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS10644305B2Battery electrode structure and method for fabricating the same

Publication Date: 2020.05.05 IND TECH RES INST

AI summary

A battery electrode structure includes a substrate, a first conductive layer and a plurality of active particles. The substrate has a substrate surface. The first conductive layer is disposed on the substrate surface. Each of the active particles has a first portion conformally engaged with a surface of the first conductive layer and a second portion protruding outwards from the surface of the first conductive layer.