Cracked Electrode Structure for High-Loading Li-Ion Batteries
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Solution Overview
Problem
Current lithium-ion batteries lack improved energy density, charge/discharge rate capabilities, and cycling stability, which are essential for emerging applications in electronics, electric vehicles, and other industries.
Innovation Solution
The development of electrodes with a plurality of cracks and islands, which resist delamination from the substrate, allowing for higher active material loading and improved ion transfer through pathways defined by the cracks, enhancing energy density and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If active material loading is increased to improve energy density, then energy density is improved, but delamination from the substrate occurs
Solution Approach 1:
The electrode body is segmented into multiple regions separated by cracks, creating isolated islands of active material. This segmentation allows the electrode to accommodate higher active material loading while the cracks act as stress relief zones that prevent delamination from the substrate.
Solution Approach 2:
The electrode incorporates a network of cracks and pores that create a porous structure. This porous architecture increases the surface area for electrolyte contact and provides pathways for ion transport, while also preventing delamination by distributing mechanical stresses throughout the electrode body.
2Speed
If ion diffusion distance is reduced to improve charge/discharge rate, then charge/discharge rate is improved, but electrode surface area is reduced
Solution Approach 1:
The crack network introduces a new dimensional pathway for ion transport. Instead of ions diffusing through a single thick electrode layer, the cracks create shortcut pathways that reduce the effective diffusion distance while maintaining a large overall electrode surface area through the three-dimensional crack network.
Solution Approach 2:
The porous crack structure provides multiple interconnected pathways for ion transport throughout the electrode. This increases the effective surface area accessible to the electrolyte while reducing the average diffusion distance ions must travel to reach active material sites.
3Productivity
If cracks are introduced to improve ion transfer, then ion transfer is improved, but electrode structural integrity is reduced
Solution Approach 1:
The cracks are strategically distributed throughout the electrode body, creating regions of different properties. The crack regions provide ion transfer pathways, while the islands of intact active material maintain structural integrity. This local differentiation allows simultaneous improvement of ion transfer and maintenance of strength.
Solution Approach 2:
The electrode functions as a composite structure with two distinct phases: the crack network providing ion transport pathways and the islands of active material providing structural integrity. This composite architecture allows the electrode to benefit from both improved ion transfer and maintained mechanical strength.
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 increases energy density, charge/discharge rate capabilities, and cycling stability by reducing ion diffusion distances and increasing the electrode's surface area in contact with the electrolyte, thereby addressing the limitations of existing lithium-ion batteries.
Implementation Method 1
a plurality of cracks defined in a first surface of the body formed by evaporation of the additive material during the drying of the slurry
Data Source
AI summary
This disclosure is directed an electrode and methods of making an electrode. The electrode includes a substrate and a body laminated to the substrate. The body includes an active material and an inactive material. A plurality of pores are defined by the body. A plurality of cracks are defined in a first surface of the body and a plurality of islands are defined in the first surface of the body. The plurality of cracks are wholly or partially surrounded by respective cracks of the plurality of cracks.