Electrode Collar Stop Filament for Intercalation Control
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Solution Overview
Problem
Existing electrode technologies face challenges in optimizing the distribution and amount of donor acceptor material along the support filament, leading to inefficiencies in electrochemical reactions and battery performance.
Innovation Solution
The electrode design incorporates a substrate with a support filament, an intercalation layer, and strategically positioned collar stops and support caps to control the distribution of donor acceptor material, creating regions with varying amounts of material to enhance electrochemical reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform donor acceptor material is applied along the entire support filament, then manufacturing is simple, but electrochemical reaction efficiency is suboptimal
Solution Approach 1:
The patent applies different amounts of donor acceptor material to different regions of the support filament. Specifically, the collar stop region receives a first amount of material while the distal region receives a second amount, creating localized variations in material concentration that optimize electrochemical reactions in each zone according to their specific functional requirements.
2Quantity of substance
If more donor acceptor material is used throughout the electrode, then charge capacity increases, but material cost and electrode weight increase
Solution Approach 1:
The patent strategically concentrates donor acceptor material in specific regions (collar stop and distal regions) rather than uniformly distributing it throughout the entire support filament. This localized material distribution achieves high charge capacity in the regions that require it most, while reducing unnecessary material in other areas, thereby optimizing the weight-capacity ratio.
3Manufacturing precision
If uniform thickness of intercalation layer is applied, then manufacturing precision is easier to maintain, but electrochemical performance is suboptimal
Solution Approach 1:
The patent deliberately creates non-uniform intercalation layer thickness by controlling the deposition process to apply different amounts of donor acceptor material to different regions. The collar stop region and distal region have intentionally different material concentrations, which optimizes electrochemical performance by matching material distribution to the specific functional requirements of each zone.
4Productivity
If collar stop structure is added to control material distribution, then electrochemical efficiency improves, but device complexity increases
Solution Approach 1:
The support filament is segmented into distinct functional regions by the collar stop structure. This segmentation divides the continuous filament into a collar stop region and a distal region, each receiving controlled amounts of donor acceptor material. The segmentation enables differentiated material distribution that optimizes electrochemical efficiency in each zone while maintaining an overall simple filament architecture.
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 improves charge capacity and cycle life by ensuring optimal distribution of intercalation material, leading to enhanced battery performance and durability.
Implementation Method 1
an intercalation layer including a donor acceptor material configured to receive a reactant of an electrochemical reaction
Data Source
AI summary
An electrode including structures configured to prevent an intercalation layer from detaching from the electrode and/or a structure configured to create a region on the electrode having a lower concentration of intercalation material. The electrode includes a support filament on which the intercalation layer is disposed. The support filament optionally has nano-scale dimensions.