Double-Sided Electrode Design for Lithium-Ion Battery Energy Density

Solution Overview

Problem

Conventional lithium-ion batteries have a high ratio of non-active materials such as separators and current collectors, which decreases energy density, increases costs, and poses manufacturing challenges.

Innovation Solution

The design incorporates a double-sided electrode with a current collector between two electroactive material layers, each separated by single-sided electrodes and separators, reducing the amount of non-active materials and improving energy density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional lithium-ion batteries use multiple separators and current collectors to physically separate electrodes, then electrode separation and safety are improved, but the ratio of non-active materials increases and energy density decreases

Engineering Contradiction:

Improveelectrode separationVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent combines the separator and current collector functions into a single integrated component. The current collector is designed with separator material attached to one surface, eliminating the need for separate separator components. This merging reduces the total amount of non-active materials while maintaining both electrode separation and electrical conductivity functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated current collector- separator component performs multiple functions simultaneously: it provides electrical conductivity for current collection, physical separation between electrodes, and structural support. This multi-functionality reduces the number of separate components needed in the battery assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional lithium-ion batteries use multiple separators and current collectors, then electrode separation is achieved, but manufacturing complexity and costs increase

Engineering Contradiction:

Improveelectrode separationVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the separator and current collector functions into a single integrated component. The current collector is designed with separator material attached to one surface, eliminating the need for separate separator components. This merging reduces the total amount of non-active materials while maintaining both electrode separation and electrical conductivity functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated current collector- separator component performs multiple functions simultaneously: it provides electrical conductivity for current collection, physical separation between electrodes, and structural support. This multi-functionality reduces the number of separate components needed in the battery assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If conventional lithium-ion batteries use multiple separators and current collectors, then electrode separation is achieved, but the number of non-active materials increases and cost-effectiveness decreases

Engineering Contradiction:

Improveelectrode separationVSAvoidcost-effectiveness

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the separator and current collector functions into a single integrated component. The current collector is designed with separator material attached to one surface, eliminating the need for separate separator components. This merging reduces the total amount of non-active materials while maintaining both electrode separation and electrical conductivity functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated current collector- separator component performs multiple functions simultaneously: it provides electrical conductivity for current collection, physical separation between electrodes, and structural support. This multi-functionality reduces the number of separate components needed in the battery assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 design enhances energy density and simplifies manufacturing by minimizing the use of non-active materials, resulting in improved performance and cost-effectiveness.

Implementation Method 1

The electrochemical cell may cycle lithium ions between the double-sided electrode and the first and second single-sided electrodes

Methodology Applied

Scientific EffectElectrochemical reactions:

Data Source

PatentUS20220367848A1Double-sided electrodes and electrochemical cells including the same

Publication Date: 2022.11.17 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

The present disclosure provides an electrochemical cell that includes a double-sided electrode. The double-sided electrode includes a first electroactive material layer, a second electroactive material layer, and a current collector disposed between the first and second electroactive material layers. Each of the first and second electroactive material layers may include a plurality of electroactive material sub-films and a plurality of buffer layers disposed between adjacent electroactive material sub-films. The electrochemical cell further includes a first single-sided electrode substantially aligned with the first electroactive material layer; a first separator physically separating the first single-sided electrode and the first electroactive material layer; a second single-sided electrode substantially aligned with the second electroactive material layer; and a second separator physically separating the second single-sided electrode and the second electroactive material layer. The current collector may include at least one surface coated with an adhesive layer.