Battery Electrode Hole Density Layout for Uniform Electrolyte Wetting
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Solution Overview
Problem
The challenge of incomplete electrolyte wetting during the manufacturing of large-sized rechargeable battery electrodes leads to non-uniform impregnation, localized electrode reactions, increased impregnation time, and reduced battery productivity, posing safety risks and shortening the battery's lifespan.
Innovation Solution
The electrode design incorporates varying hole densities in the active material layer, with denser holes in areas of poor impregnation and sparser holes in well-impregnated areas to enhance uniform electrolyte impregnation, reducing impregnation time, and improving ion mobility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the size of electrode plates increases to increase battery capacity, then the battery capacity increases, but the electrolyte wetting becomes incomplete and impregnation time increases
Solution Approach 1:
The electrode plate incorporates a porous layer with controlled porosity (30-70%) that facilitates electrolyte penetration throughout the electrode structure. The porous network allows electrolyte to reach internal regions more efficiently, reducing impregnation time while maintaining the increased electrode size required for higher battery capacity.
Solution Approach 2:
The electrode structure features non-uniform porosity distribution where the porous layer has different porosity characteristics in different regions. This local variation in pore density and size allows optimized electrolyte flow paths that adapt to the increased electrode dimensions, ensuring complete wetting across the entire electrode area regardless of its large size.
2Quantity of substance
If the size of electrode plates increases to increase battery capacity, then the battery capacity increases, but the uniformity of electrode state deteriorates leading to localized electrode reactions
Solution Approach 1:
The porous layer provides a uniform three-dimensional network structure that ensures consistent electrolyte distribution across the entire electrode plate. This uniform porous architecture prevents localized concentration gradients and ensures homogeneous electrode reactions throughout the large electrode area, maintaining manufacturing precision despite increased size.
Solution Approach 2:
The electrode employs spatially varying porosity where different regions have optimized pore characteristics tailored to their specific locations. This local quality adjustment ensures that electrolyte penetration and reaction uniformity are maintained across all regions of the large electrode plate, preventing localized reactions and maintaining overall uniformity.
3Quantity of substance
If the size of electrode plates increases to increase battery capacity, then the battery capacity increases, but productivity decreases due to increased impregnation time
Solution Approach 1:
The porous layer with optimized porosity (30-70%) creates efficient fluid transport pathways that dramatically reduce electrolyte impregnation time. This allows large electrode plates to be manufactured with complete electrolyte saturation achieved rapidly, thereby maintaining high productivity despite the increased electrode size required for higher battery capacity.
Solution Approach 2:
The non-uniform porosity distribution optimizes electrolyte flow dynamics across different regions of the electrode plate. This local optimization ensures that impregnation proceeds efficiently throughout the entire electrode area simultaneously, reducing overall impregnation time and maintaining high manufacturing productivity for large-capacity batteries.
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 approach achieves faster and more uniform electrolyte impregnation, enhances battery productivity, and reduces lithium precipitation, leading to improved fast-charging capabilities and extended battery lifespan.
Implementation Method 1
an active material layer that is formed on the substrate, includes a plurality of holes
Data Source
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AI summary
An electrode for a rechargeable battery according to one or more embodiments of the present disclosure includes: a substrate; and an active material layer that is formed on the substrate, includes a plurality of holes, and includes a first density portion and a second density portion. The first density portion has a higher density than that of the second density portion, the second density portion has a lower density than that of the first density portion, and the second density portion is disposed at both sides (e.g., opposite sides) of the first density portion.