Carbon Substrate Cathode for Alkali Metal-Sulfur Batteries

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Solution Overview

Problem

Conventional alkali metal-sulfur batteries face limitations in achieving high energy density and long-term stability due to the high weight and cost of metallic current collectors, which also suffer from corrosion issues.

Innovation Solution

A cathode unit for alkali metal-sulfur batteries utilizing a carbon substrate as the current collector, eliminating the need for metallic substrates, with a carbon substrate configured as a self-supporting flat structure or applied to a carrier substrate, ensuring high conductivity and electrical contact with electrochemically active components like sulfur and alkali metal sulfides.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If metallic current collectors are used, then good electrical contact and structural stability are achieved, but weight increases and energy density decreases

Engineering Contradiction:

Improveelectrical contact stabilityVSAvoidcurrent collector weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent replaces expensive, heavy metallic current collectors with a lighter carbon-based current collector that can be disposed of or replaced more easily. The carbon substrate provides sufficient electrical conductivity for the battery's operational lifetime while significantly reducing overall battery weight and cost.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent employs a composite structure where a carbon-based material serves as the current collector substrate, combining light weight with adequate electrical conductivity. This composite approach allows the battery to achieve lower weight while maintaining necessary electrical performance through the carbon material's inherent properties.

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If metallic current collectors are used, then structural stability is achieved, but cost increases

Engineering Contradiction:

Improvecurrent collector stabilityVSAvoidproduction cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent substitutes expensive metallic materials with cheaper carbon-based materials for the current collector. This substitution reduces material costs significantly while the carbon substrate maintains adequate structural stability for the battery's intended lifespan, making the overall manufacturing process more cost-effective.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The use of carbon-based composite materials provides a cost-effective alternative to traditional metals. The carbon substrate offers sufficient mechanical and electrical properties at a lower cost, enabling more economical battery production while maintaining necessary performance standards.

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If carbon substrate is used as current collector, then weight is reduced and energy density increases, but manufacturing complexity increases

Engineering Contradiction:

Improvecurrent collector weightVSAvoidproduction process complexity

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The patent extracts the current collector function from traditional metallic substrates and implements it using a carbon-based material that can be produced through simpler, more direct processes. This extraction allows for a streamlined manufacturing approach that reduces overall production complexity despite the material change.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the material parameter from metal to carbon, which fundamentally alters the manufacturing approach. The carbon substrate can be produced and processed with different, potentially simpler techniques that reduce manufacturing steps and overall process complexity compared to traditional metallic current collector fabrication.

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

This configuration enhances energy density, improves cycling stability, and simplifies production while reducing material costs, as the carbon substrate acts both as a collector and reaction surface, allowing for efficient electron flow and durable battery performance.

Implementation Method 1

a cathode collector comprising a carbon substrate, an electrochemically active component which is selected from sulfur and an alkali metal sulfide and is in electrically conductive contact with the carbon substrate

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS10090528B2Cathode unit for an alkaline metal/sulfur battery having an optimised arrester structure

Publication Date: 2018.10.02 FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV

AI summary

The invention relates to a cathode unit for an alkaline metal/sulphur battery, containing a cathode arrester, which comprises a carbon substrate, and an electrochemically active component, which is selected from sulphur or an alkaline metal sulphide and is in electrically conductive contact with the carbon substrate.