Electrode Membrane With Through-Pins for Low Ohmic Resistance

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Solution Overview

Problem

Existing electrochemical cells face challenges in achieving low ohmic resistance due to interfacial layers between electrodes and current collectors, leading to inefficient charge transfer and limited energy storage capacity.

Innovation Solution

The use of an electrically conductive cohesive galvanic membrane with metal pins extending through it, which saturate the membrane pores and surfaces without piercing or displacing them, allowing for direct metallic contact and eliminating dielectric interfacial layers, thereby reducing ohmic resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an interfacial layer of electrolyte or gap is present between the metal current collector surface and the overlying membrane, then the membrane can be properly formed and attached, but ohmic resistance increases leading to heat loss (i²R)

Engineering Contradiction:

Improvemembrane attachmentVSAvoidohmic resistance

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The invention extracts and eliminates the interfacial layer of electrolyte or gap between the metal current collector surface and the membrane. By removing this harmful intermediate layer, the patent achieves direct metallic contact between the current collector and the membrane, thereby eliminating ohmic resistance and associated heat loss while maintaining reliable membrane attachment.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of operation

If conventional electrode structures with brushes or coatings are used to connect active chemistry to current collector, then electrical connection is established, but specific area electrode ohmic resistance increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidspecific area electrode ohmic resistance

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The invention replaces the mechanical brush or coating connection system with a direct metallic contact system. Instead of using brushes that rely on physical contact through an interfacial layer, the patent employs a current collector with exposed metal surfaces that make direct metallic contact with the membrane, substituting a high-resistance mechanical connection with a low-resistance metallic bond.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of energy

If metal wafer anodes are used for compact energy storage, then connection to current collector is improved, but access to electrolyte is limited

Engineering Contradiction:

Improveconnection efficiencyVSAvoidelectrolyte access

Core Design Contradiction:

Loss of energyVSAdaptability or versatility

Solution Approach 1:

The invention uses a porous membrane structure that allows electrolyte to penetrate and access the active chemistry throughout the membrane volume. The porous structure provides channels for electrolyte flow while maintaining direct metallic contact with the current collector, thereby resolving the contradiction between good electrical connection and adequate electrolyte access.

Inventive Principle:

Principle #31Porous materials

4Ease of operation

If conductive powders are used as charge transfer medium, then charge transfer is enabled, but wiring of chemistry to current collector is poor and ohmic resistance increases

Engineering Contradiction:

Improvecharge transferVSAvoidohmic resistance

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The invention employs a composite membrane structure that combines conductive materials with the membrane matrix, creating a integrated charge transfer pathway. This composite structure provides both the charge transfer capability and the direct metallic connection to the current collector, eliminating the need for separate conductive powder layers that suffer from poor wiring and high resistance.

Inventive Principle:

Principle #40Composite 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

This configuration achieves ultralow resistance charge transfer and enhanced energy storage capacity by ensuring continuous electrical conductivity with minimal energy loss, improving ion mobility and dimensional stability across various electrolytes.

Implementation Method 1

metal pins extending through the membrane from the first surface to the second surface... the pins electrically coupled to the current collector... saturate the membrane pores and surfaces

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

electrically conductive cohesive membrane... continuous electrical conductivity with minimal energy loss... reducing ohmic resistance

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20220320539A1Unique electrodes for electrochemical cells

Publication Date: 2022.10.06 GLOBAL ENERGY SCIENCES LLC

AI summary

An electrode for electrochemical cells including an electrically conductive cohesive membrane having a thickness defined by a first surface and a second surface opposite the first surface; ohmic impedance independent of membrane thickness; simultaneous uniform charge/discharge throughout membrane thickness; the membrane comprising open cell pores and surfaces; a current collector electrically strongly coupled to the entire membrane thickness; and pins extending through the membrane from the first surface to the second surface; the pins electrically coupled to the current collector having eliminated prior art problematical interfacial layers.