Free-Standing 3D Anode With Ion-Conducting Network Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional three-dimensional (3D) anode structures for lithium-based and sodium-based batteries suffer from issues such as volumetric changes, dendrite formation, and parasitic side reactions, leading to capacity loss, reduced power output, and safety hazards like cell rupture.
Innovation Solution
A free-standing, three-dimensional monolithic anode structure with a continuous ion-conducting network is developed, where the anode active material itself serves as a substrate, and ion-conducting materials are homogeneously distributed to enhance ionic conductivity and prevent dendrite formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional 3D anode structures are used, then surface area is increased, but ion diffusion pathways are limited and dendrite formation occurs
Solution Approach 1:
The patent employs a porous ceramic coating layer with controlled porosity (30-70%) that provides continuous ion diffusion pathways throughout the 3D anode structure. The porous network allows uniform lithium ion transport while preventing dendrite penetration, resolving the contradiction between high surface area and reliable ion diffusion.
Solution Approach 2:
The patent creates a composite structure combining metal foam substrate with ceramic coating layer (e.g., LiNbO3, Li2SiO3). This composite approach integrates the high surface area of 3D metal foam with the ion-conducting and dendrite-preventing properties of ceramic materials, simultaneously achieving both improved surface area and enhanced reliability.
2Quantity of substance
If lithium-based materials are used, then capacity is increased, but volumetric changes cause cell failure and safety issues
Solution Approach 1:
The patent applies a thin ceramic coating layer (5-50 μm) that acts as a protective shell accommodating volumetric changes of lithium during cycling. This flexible-protective layer maintains structural integrity during expansion and contraction, preventing cell failure while preserving high capacity.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the anode by applying ceramic coatings with specific pore sizes (0.5-10 μm) and thicknesses (5-50 μm). These parameter changes enable the structure to accommodate volumetric variations of lithium during cycling, maintaining stability while preserving high capacity.
3Quantity of substance
If high surface area substrates are used, then reaction sites are increased, but parasitic side reactions with electrolytes increase
Solution Approach 1:
The patent introduces a ceramic coating layer as an intermediary between the metal foam substrate and the electrolyte. This intermediate layer provides ion conduction pathways while blocking direct contact between electrolyte and metal, thereby reducing parasitic side reactions while maintaining high reaction site availability.
Solution Approach 2:
The ceramic coating creates an inert environment around the reactive metal foam substrate, preventing direct parasitic reactions with the electrolyte. The coating materials (e.g., LiNbO3, Li2SiO3) are chemically stable and form protective barriers that eliminate harmful side reactions while allowing ion transport.
4Stability of the object's composition
If 3D monolithic structure is used, then structural stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the anode manufacturing into separate stages: first forming the metal foam substrate, then applying the ceramic coating layer. This segmentation allows each component to be manufactured using established techniques independently, reducing overall manufacturing complexity while achieving the stable 3D monolithic structure.
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 solution provides improved cycling stability, high-rate capability, and extended cycle life by maintaining a stable volume and minimizing dendrite formation, resulting in higher energy density and specific capacity.
Implementation Method 1
a continuous ion-conducting network formed on surface(s) and/or in a bulk of the 3D monolith, where the ion-conducting network comprises one or more ion-conducting materials
Implementation Method 2
at least one anode active material selected from the group consisting of: lithium metal, one or more lithium alloys, one or more lithium composite materials
Data Source
AI summary
Current collectors are critical components of conventional electrochemical cell design, and serve to conduct electricity generated within the electrochemical cell to an external environment of the electrochemical cell, typically to a machine or device electrically coupled to the electrochemical cell, e.g. via a plurality of leads, tabs, contacts, terminals, etc. Accordingly, current collectors conventionally comprise one or more highly electrically conductive (and, optionally, thermally conductive) materials, most often metal(s) or alloy(s) of iron, nickel, copper, etc. As a result, current collectors often represent a substantial contribution to the total mass of the electrochemical cell, and undesirably reduce the power-to-weight ratio of the resulting battery. The presently disclosed inventive concepts include various configurations of free-standing electrodes that do not require a distinct current collector component to efficiently conduct electricity to external devices, and include unique compositions and structural arrangements that collectively convey substantial performance improvements on electrochemical cells implementing the same.