Electrode Structure for Electrochemical Cell Using Porous Support

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Solution Overview

Problem

Existing electrochemical cells face limitations in achieving high bulk electrical conductivity and structural stability due to insufficient contact between electrode active material and electrolyte, and the use of bulky current collectors that reduce energy density and specific energy.

Innovation Solution

The implementation of an electrode structure comprising a first porous support structure within the pores of a second, electrically conductive porous support structure, allowing for enhanced bulk electrical conductivity and structural integrity by distributing electrode active material evenly throughout the electrode.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a separate current collector is used to maintain structural stability, then structural stability is improved, but device complexity and weight increase

Engineering Contradiction:

Improvestructural stabilityVSAvoiddevice complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent merges the current collector function with the porous support structure by making the support structure itself electrically conductive. This eliminates the need for a separate current collector while maintaining structural stability and electrical conductivity, directly resolving the contradiction between structural stability and device complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The porous support structure is designed to perform multiple functions simultaneously: providing structural stability, maintaining porosity for electrolyte access, and conducting electricity. This multi-functionality eliminates the need for separate components and reduces overall device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If porous electrodes are used to increase contact between active material and electrolyte, then electrochemical reaction rate is improved, but bulk electrical conductivity deteriorates

Engineering Contradiction:

Improveelectrochemical reaction rateVSAvoidbulk electrical conductivity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs a porous support structure that provides extensive surface area and pore networks for electrolyte penetration, increasing contact between active material and electrolyte. The porosity is optimized to maintain both high reaction rates and adequate electrical conductivity pathways

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The electrode is designed as a composite structure combining porous support material with electrically conductive components. This composite approach allows the porous structure to provide electrolyte access while the conductive phases maintain bulk electrical conductivity, resolving the contradiction between reaction rate and conductivity

Inventive Principle:

Principle #40Composite materials

3Strength

If bulky current collectors are used to maintain structural integrity, then structural integrity is improved, but energy density and specific energy deteriorate

Engineering Contradiction:

Improvestructural integrityVSAvoidenergy density

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

By merging the current collector function into the porous support structure, the patent eliminates the need for bulky separate current collectors. This reduction in unnecessary material increases the proportion of active material in the electrode, thereby improving energy density and specific energy while maintaining structural integrity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The porous support structure acts as a thin, lightweight framework that provides structural integrity without the bulk of traditional current collectors. This thin-film approach minimizes non-active material volume and maximizes energy density

Inventive Principle:

Principle #30Flexible shells and thin films

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 improves the energy density and specific energy of electrochemical cells by eliminating the need for a separate current collector and maintaining structural stability under anisotropic forces, while ensuring high electrode active material utilization and prolonged cycle life.

Implementation Method 1

a second, electrically conductive porous support structure

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Implementation Method 2

porous electrodes comprising an electrode active material positioned on or within a support structure

Methodology Applied

Scientific EffectPorosity: Porosity

Data Source

PatentUS9077041B2Electrode structure for electrochemical cell

Publication Date: 2015.07.07 SION POWER CORP

AI summary

The present invention relates to the use of porous structures comprising electrode active materials, which can be used as electrodes in electrochemical cells. In certain embodiments, the electrodes described herein can comprise a first porous support structure (e.g., a plurality of particles, which can be porous in certain cases) in which electrode active material is at least partially contained. The first porous support structure can be, in some embodiments, at least partially contained within the pores of a second porous support structure (e.g., an agglomeration of elongated fibers, a porous web formed by sintered particles, etc.) containing pores that are larger than the components of the first porous support structure.