Solid-State Battery Electrode Foam Columns for Contact Stability

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional solid-state batteries experience significant dimensional changes during charging and discharging due to lithium intercalation and volume expansion, leading to contact issues between battery layers and reduced cycle life, which existing protective polymer layers fail to adequately address.

Innovation Solution

Incorporating foam cushion columns within and extending from the surface of the current collector to absorb pressure changes and act as a spring, reducing volume changes from 4-10% to 1-2% by acting as a dimension retainer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional protective polymer layers are used between the anode and solid electrolyte, then contact issues are partially mitigated, but the polymer material reduces electrode conductivity, reacts with solid electrolyte, and fails to sufficiently accommodate 4-10% dimensional changes

Engineering Contradiction:

Improvecontact stability between layersVSAvoidpolymer reaction with solid electrolyte and conductivity reduction

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent introduces a foam cushion layer as an intermediary component between the anode and solid electrolyte. This foam cushion serves as a mediator that absorbs dimensional changes (4-10% expansion/contraction) during charging/discharging cycles, preventing direct contact and reaction between the polymer protective layer and solid electrolyte, thereby eliminating the harmful chemical reactions while maintaining contact stability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the physical state and properties of the protective layer by using a foam cushion with high porosity (80-95%) instead of a dense polymer layer. The foam's compressible structure allows it to dynamically change volume in response to dimensional changes, absorbing expansion forces and maintaining stable contact without the chemical reactivity issues of conventional polymer layers

Inventive Principle:

Principle #35Parameter changes

2Reliability

If high pressure is applied to reduce expansion changes, then dimensional stability is improved, but the complexity of the battery structure and construction increases

Engineering Contradiction:

Improvedimensional stabilityVSAvoidbattery structure and construction

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The foam cushion layer provides self-regulating dimensional stability through its inherent compressible structure. During charging, the foam automatically compresses to accommodate anode expansion; during discharging, it rebounds to maintain contact. This self-service mechanism eliminates the need for external pressure application systems, reducing structural complexity while maintaining dimensional stability

Inventive Principle:

Principle #25Self-service

3Reliability

If a protective polymer layer is added between active material layers, then contact issues are addressed, but energy density is reduced

Engineering Contradiction:

Improvecontact stabilityVSAvoidenergy density

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent employs a porous foam cushion material with 80-95% porosity as the protective layer. The high porosity allows the foam to accommodate dimensional changes through compression of void spaces rather than requiring additional material volume. This enables the protective function to be achieved with minimal material addition, thereby preserving energy density while maintaining contact stability

Inventive Principle:

Principle #31Porous materials

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

The foam cushion columns effectively accommodate volume changes, maintaining stable contact between battery layers and enhancing cycle life by absorbing pressure increases and decreases during charging and discharging.

Implementation Method 1

the foam cushion absorbs the pressure increase and acts as a spring that can contract under pressure... and can re-expand when the pressure is reduced

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the foam cushion columns effectively accommodate volume changes, maintaining stable contact between battery layers and enhancing cycle life by absorbing pressure increases and decreases during charging and discharging

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS12431506B2Electrode including dimension retainer for solid-state battery

Publication Date: 2025.09.30 NISSAN NORTH AMERICA INC

AI summary

An electrode is provided that includes a current collector, at least one column and an electrode material. The at least one column is formed of a foam material. The electrode material is disposed on the current collector and includes an electrode active material. Each of the at least one column is disposed within and extending from a surface of the current collector.