Embroidered Electrode for Galvanic Cell Current Distribution
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Solution Overview
Problem
Existing electrochemical cells face challenges in achieving optimized current distribution and maintaining high energy and power densities, especially as the active mass thickness increases, leading to reduced efficiency and mechanical sensitivity.
Innovation Solution
An embroidered electrode structure is created using an electrically insulating carrier with conductive embroidery, varying thread number and density, and air embroidery techniques to form a three-dimensional conductive structure, allowing for homogeneous current distribution and high energy and power densities even in thicker active masses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the active mass layer is made thicker to increase energy storage capacity, then the energy storage capacity increases, but the electrical conductivity decreases and internal resistance increases
Solution Approach 1:
The patent transitions from traditional two-dimensional planar electrodes to three-dimensional porous electrode structures. This dimensional change allows the active mass to be distributed throughout a volumetric network with integrated conductive pathways, enabling thick active layers to maintain electrical conductivity through multiple transport routes rather than relying on single-plane conduction.
Solution Approach 2:
The electrode structure employs spatially varying properties where conductive materials are distributed non-uniformly throughout the porous matrix. The conductive network density and composition are optimized at different locations and depths within the active mass, ensuring adequate electrical conductivity throughout the entire thick layer while maximizing energy storage capacity.
2Quantity of substance
If the active mass layer is made thicker to increase energy density, then the energy density increases, but the charging rate is limited by current transfer
Solution Approach 1:
The three-dimensional porous structure creates multiple parallel current transfer pathways from the electrolyte through the conductive network to the active mass. This volumetric arrangement dramatically reduces the effective transport distance for charge transfer compared to planar structures, enabling high charging rates even in thick active layers by distributing the current transfer load across numerous simultaneous reaction sites.
Solution Approach 2:
The continuous thick active mass is effectively segmented into numerous smaller functional units distributed throughout the porous volume. Each local region acts as an independent electrochemical reaction zone with its own conductive pathways, allowing parallel current transfer through many small channels rather than one large path, thereby increasing overall charging speed.
3Reliability
If conventional conductive structures are used in thick active masses, then conductivity is improved, but current distribution remains non-uniform and efficiency decreases
Solution Approach 1:
The conductive network is designed with spatially varying characteristics where material composition, pore size, and conductive phase distribution are optimized at different locations within the electrode. This local optimization ensures that current density is distributed more uniformly throughout the entire active mass by compensating for variations in path length and resistance at different positions, achieving both high conductivity and uniform current distribution simultaneously.
Data Source
Figure 1~2
Figure 3~4
AI summary
Electrode for a galvanic cell, characterized by a carrier with embroidery, at least part of the surface of the embroidery being electrically conductive.