Electrode Microchannel Structure for Faster Electrolyte Filling
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Solution Overview
Problem
The existing manufacturing process of lithium-ion batteries is hindered by the slow filling of liquid electrolyte into electrode assemblies due to the low porosity and high tortuosity of microporous materials, leading to increased manufacturing time and cost.
Innovation Solution
Incorporating microchannels in the base layers of electrodes, which are aligned horizontally with respect to the current collector, facilitates faster electrolyte filling by providing a less-tortuous path for electrolyte invasion and air removal, improving wettability and contact between the electrolyte and electrode components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If microporous materials with low porosity and high tortuosity are used in electrode base layers, then manufacturing precision and structural integrity are maintained, but electrolyte filling speed decreases and manufacturing time increases
Solution Approach 1:
The base layer is segmented into multiple channels with different porosity and tortuosity characteristics. The microchannel network divides the electrolyte filling path into multiple parallel routes, reducing the effective tortuosity and enabling faster electrolyte penetration throughout the electrode structure while maintaining structural integrity through the distributed channel architecture
Solution Approach 2:
Different regions of the base layer are assigned different local properties: regions closer to the electrolyte inlet have higher porosity and lower tortuosity to facilitate rapid electrolyte entry, while regions farther away gradually transition to lower porosity and higher tortuosity to maintain structural support and prevent short-circuiting, creating an optimized gradient structure for electrolyte distribution
2Productivity
If microchannels are incorporated in the base layer to improve electrolyte filling speed, then electrolyte invasion becomes less tortuous and wettability improves, but device complexity increases
Solution Approach 1:
The microchannel network is nested within the existing base layer structure, with channels formed as voids or pathways through the porous matrix material. This nested architecture allows the complex channel network to be integrated within the conventional electrode structure without requiring separate components, reducing overall device complexity while maintaining the electrolyte transport benefits
Solution Approach 2:
The base layer utilizes porous materials with controlled pore size distribution and connectivity to form the microchannel network. The porous structure naturally provides the necessary channels for electrolyte flow while maintaining mechanical integrity, eliminating the need for additional structural elements and simplifying the overall device design
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 approach significantly reduces the time required to fill the electrolyte, enhances the wettability of electrode pores, and improves cell performance and cycle life, thereby reducing manufacturing time and overall costs.
Implementation Method 1
the presence of the microchannels in the base layer(s) reduces the time required to fill the liquid electrolyte into the electrode assembly... provides a less-tortuous path for electrolyte invasion
Implementation Method 2
the presence of the microchannels in the base layer(s) improves the wettability of the electrode assembly, thereby increasing the extent of contact between the liquid electrolyte and the components of the electrode assembly
Data Source
AI summary
Provided is an electrode comprising a current collector, a base layer on a surface of the current collector, and an active material (e.g., cathode, anode) layer on the base layer. The base layer comprises microchannels that are at least partially horizontally aligned with respect to the first surface of the current collector. Also provided are methods for preparing electrodes and electrode assemblies, and methods of filling liquid electrolyte into electrode assemblies. Electric vehicle systems comprising the electrode assemblies are also provided.