Electrochemical Cell Interlayer for Dendrite Growth Prevention

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Dendrite formation in electrochemical cells leads to short circuiting and heat generation, posing safety risks such as fires and thermal runaway.

Innovation Solution

Incorporating an interlayer with electroactive material between the anode and cathode, along with a battery management system (BMS) to detect and manage dendrite growth, including methods to dissolve or prevent dendrites using voltage modulation and energy discharge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If dendrites are allowed to grow in electrochemical cells, then the cell can operate, but short circuiting and heat generation occur leading to safety risks

Engineering Contradiction:
ImprovesafetyVSAvoidshort circuiting and heat generation
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

An interlayer is introduced between the anode and cathode as an intermediary component. This interlayer includes electroactive material and is connected to a power source that maintains a voltage difference below a threshold value (about 0.01 V), thereby preventing dendrite formation without disrupting normal cell operation.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The voltage difference between the cathode and interlayer is controlled to remain below a specific threshold (about 0.01 V). This parameter control prevents the conditions necessary for dendrite formation while maintaining normal electrochemical cell function.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If an interlayer with electroactive material is added to prevent dendrites, then safety is improved, but device complexity increases

Engineering Contradiction:
ImprovesafetyVSAvoidcell structure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The interlayer serves multiple functions: it acts as a separator between electrodes, provides electroactive material for energy storage, and prevents dendrite formation through voltage control. This multi-functionality reduces the need for additional dedicated safety components.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The dendrite prevention function is merged with the separator and electroactive material layers. Rather than adding a separate safety mechanism, the interlayer combines structural separation with active dendrite prevention through its electrochemical properties and voltage control.

Inventive Principle:
Principle #5Merging (Combining)

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

Prevents dendrite growth, reducing safety hazards by detecting and mitigating dendrites before they cause damage, ensuring safe operation of electrochemical cells.

Implementation Method 1

a power source electrically connected to the proximal end of the cathode and the proximal end of the interlayer, the power source configured to maintain a voltage difference between the cathode and the interlayer below a threshold value

Methodology Applied
Scientific EffectVoltage control: Electric Field

Implementation Method 2

an anode disposed on an anode current collector, a cathode disposed on a cathode current collector

Methodology Applied
Scientific EffectElectrochemical reaction: Redox Reactions

Data Source

PatentUS12580231B2Systems and methods for minimizing and preventing dendrite formation in electrochemical cells
Publication Date: 2026.03.17 24M TECHNOLOGIES INC
  • US12580231B2 patent drawing
  • US12580231B2 patent drawing
  • US12580231B2 patent drawing

AI summary

Embodiments described herein relate to electrochemical cells with dendrite prevention mechanisms. In some aspects, an electrochemical cell can include an anode disposed on an anode current collector, a cathode disposed on a cathode current collector, the cathode having a first thickness at a proximal end of the cathode and a second thickness at a distal end of the cathode, the second thickness greater than the first thickness, a first separator disposed on the anode, a second separator disposed on the cathode, an interlayer disposed between the first separator and the second separator, the interlayer including electroactive material and having a proximal end and a distal end, and a power source electrically connected to the proximal end of the cathode and the proximal end of the interlayer, the power source configured to maintain a voltage difference between the cathode and the interlayer below a threshold value.