Composite Electrode Foil Structure for Thin-Film Stability
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Solution Overview
Problem
Existing electrode foils in electrical energy storage devices face limitations in mechanical stability, particularly in thickness, which hinders their processing and functionality, especially for applications requiring thin foils for high capacity and efficiency.
Innovation Solution
A foil-like functional material is developed with a support medium formed from construction materials and sheathed with a first functional material, where the remaining volume is filled with a second functional material, optimizing mechanical stability and electrical conductivity by using a matrix of linear and node-shaped support elements with interconnected partial volumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of electrode foils is reduced to increase capacity and efficiency, then energy storage capability is improved, but mechanical stability deteriorates
Solution Approach 1:
The invention uses a composite structure consisting of a support medium (foil or textile) combined with functional materials (conductive layers and active materials). This composite approach allows the support medium to provide mechanical stability while the functional materials provide electrical conductivity and energy storage, resolving the contradiction between thinness and mechanical strength.
Solution Approach 2:
The invention applies different materials with specific properties to different regions or layers: the support medium provides mechanical strength, conductive layers provide electrical conductivity, and active materials provide energy storage. This local optimization of material properties allows the foil to be thin overall while maintaining necessary mechanical stability through the structured composite design.
2Volume of moving object
If the volume of support medium is reduced to enable thinner foils, then foil thickness is decreased, but mechanical stability deteriorates
Solution Approach 1:
The invention employs thin support media (foils or textile structures) that are optimized for minimal thickness while maintaining adequate mechanical stability through their inherent structural properties. The thin support medium is combined with functional materials to create a composite structure where the support provides just enough mechanical stability for processing and handling.
Solution Approach 2:
The composite structure combines the thin support medium with functional materials (conductive layers and active materials) to achieve the desired performance. The support medium volume is minimized for thinness, but the overall composite structure maintains mechanical stability through the synergistic combination of components.
3Ease of manufacture
If conventional electrode foil structures are used, then manufacturing is simple, but electrical conductivity and energy storage capabilities are limited
Solution Approach 1:
The invention uses a multi-layer composite structure with conductive layers and active materials applied to the support medium. This composite approach enhances electrical conductivity and energy storage capabilities compared to conventional single-material foils, while maintaining manufacturability through established coating and lamination techniques.
Solution Approach 2:
The invention incorporates porous structures in the functional materials and/or support medium to increase surface area for electrochemical reactions, thereby improving electrical conductivity and energy storage capabilities. The porous structure allows for better ion transport and increased active material loading while maintaining a foil-like overall structure.
Data Source
AI summary
A foil-like functional material (1) providing a predefined function and may be used for targeted physical, chemical, physicochemical, biological, technical and technological purposes, and in which is arranged a support medium (2), which comprises a total support volume, has a cross-sectional extent (7) of ≤100 μm, like a matrix, and is formed from linear support elements (3a) and node-like support elements (3b), which form the substance components of the support medium (2) and pass through the total support volume to form a strip-like extent with interconnected partial volumes (5), situated therein and spanned by support elements (3) close by. The support elements (3) are sheathed with a first functional substance (4) which provides a first function. The remaining volume of the total support volume is filled with one second functional substance (6) which differs from the first function.