Cathode Active Material for High-Energy Lithium-Air Batteries

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Solution Overview

Problem

Lithium-air batteries face issues with low energy density, high material costs, and poor electrochemical reversibility due to oxygen desorption and irreversible byproducts, leading to thermal runaway risks.

Innovation Solution

Development of cathode active materials formed by heating a solution of hygroscopic species and reactive oxygen species at temperatures below 400°C, combined with conductive materials and polymeric binders, which minimizes oxygen evolution during battery operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If lithium-air or lithium-oxygen batteries are used to achieve high energy density, then energy density is improved, but oxygen desorption occurs at low temperatures causing thermal runaway and poor electrochemical reversibility

Engineering Contradiction:

Improveenergy densityVSAvoidelectrochemical reversibility

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent introduces a protective coating layer as an intermediary between the cathode active material and the electrolyte. This coating prevents direct contact and harmful reactions, thereby improving electrochemical reversibility while maintaining high energy density performance

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent modifies the operating parameters by controlling the potential window and using specific catalysts to prevent oxygen desorption at low temperatures. This changes the thermal and electrochemical parameters to avoid thermal runaway while maintaining high energy density

Inventive Principle:

Principle #35Parameter changes

2Use of energy by moving object

If lithium-air or lithium-oxygen batteries are used to achieve high energy density, then energy density is improved, but oxygen desorption causes thermal runaway reactions

Engineering Contradiction:

Improveenergy densityVSAvoidthermal runaway risk

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary protective measures by forming a stable coating on the cathode before operation and selecting materials with high thermal stability. This preliminary protection prevents oxygen desorption and thermal runaway before they can occur

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The patent converts the potentially harmful oxygen evolution into a beneficial controlled process by using it during charging without allowing uncontrolled desorption. The oxygen is managed as a useful intermediate rather than a harmful byproduct

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Use of energy by moving object

If conventional cathode materials are used to achieve high energy density, then energy density is improved, but manufacturing costs increase due to expensive materials

Engineering Contradiction:

Improveenergy densityVSAvoidmanufacturing cost

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent employs cost-effective cathode materials such as metal oxides, hydroxides, or carbonates that can be obtained from abundant sources. These materials provide sufficient performance for high energy density without requiring rare or expensive elements

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent uses composite cathode structures combining different materials (e.g., metal oxides with conductive additives) to achieve high energy density through synergistic effects, reducing reliance on single expensive materials while maintaining performance

Inventive Principle:

Principle #40Composite materials

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 approach results in high energy density batteries with reduced material costs, improved reversibility, and minimal gaseous oxygen production, enhancing safety and performance.

Implementation Method 1

cathode active materials for use in cathodes of batteries, where the cathode active materials include a reactive oxygen species derivative, a reactive oxygen species derivative combined with a hygroscopic species, or a reactive oxygen species combined with a hygroscopic species, where a cathode prepared using the cathode active material evolves substantially zero gaseous oxygen during operation in the battery

Methodology Applied

Scientific EffectElectrochemical reaction:

Data Source

PatentUS11374209B1High-energy cathodes, batteries, and methods of making the same

Publication Date: 2022.06.28 WATTRII INC

AI summary

Methods of manufacturing cathode active materials, including preparing a solution of a hygroscopic species and a reactive oxygen species, heating the solution at a temperature that is less than about 400° C. for a time sufficient for a precipitate of the cathode active material to form, and collecting the cathode active material. The cathode active materials can be used to prepare cathodes that evolve little or no oxygen during operation. The cathodes can be economically incorporated into batteries that can provide high energy density.