Gel Electrolyte Additives for Metal Electrode Passivation Control

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Solution Overview

Problem

Current energy storage technologies are inadequate for long and ultralong duration energy storage beyond 8 hours, necessitating the development of low-cost, rechargeable battery chemistries that can support large-scale energy storage.

Innovation Solution

The development of an electrochemical cell with a metal-containing active material, such as iron, and an electrolyte that includes a gel and an additive. The additive is suspended in the gel and accumulates at the metal-containing active material, facilitating improved performance by reducing hydrogen evolution and enhancing charge acceptance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If conventional energy storage technologies are used, then current energy storage needs are met, but long and ultralong duration energy storage beyond 8 hours cannot be achieved

Engineering Contradiction:
Improveenergy storage durationVSAvoidperformance reliability
Core Design Contradiction:
Duration of action of moving objectVSReliability

Solution Approach 1:

The patent changes the chemical parameters of the electrolyte by introducing specific additives (such as zinc ions, calcium ions, or organic additives) that modify the electrochemical environment. This prevents the formation of passive films on metal electrodes and suppresses hydrogen evolution, enabling stable operation for long and ultralong duration energy storage while maintaining performance reliability

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent employs composite electrolyte systems combining gel matrices with specific ionic additives. This composite approach creates a multi-functional electrolyte that provides both the structural stability needed for long-duration operation and the chemical properties required to prevent electrode passivation, thereby achieving both extended duration and maintained reliability

Inventive Principle:
Principle #40Composite materials

2Productivity

If metal electrodes are used in conventional electrolytes, then electrochemical reactions occur, but passivation of the metal electrode surface reduces efficiency

Engineering Contradiction:
Improvecharge acceptanceVSAvoidCoulombic efficiency
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent introduces ionic intermediaries (such as zinc ions, calcium ions, or organic additives) into the electrolyte that act as mediators between the metal electrode and the bulk electrolyte. These intermediaries preferentially interact with the electrode surface, forming protective complexes that prevent harmful passivation reactions while allowing beneficial charge transfer, thus improving both charge acceptance and Coulombic efficiency

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent converts the naturally occurring ionic species in the electrolyte from potential sources of harm (hydrogen evolution, passivation) into beneficial agents. By carefully selecting and controlling the concentration of specific ions (such as zinc or calcium ions), the system transforms what would be parasitic reactions into protective mechanisms that enhance electrode stability and efficiency

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If low-cost rechargeable battery chemistries are used, then cost is reduced, but long and ultralong duration energy storage capability is insufficient

Engineering Contradiction:
Improvemanufacturing costVSAvoidenergy storage duration
Core Design Contradiction:
Ease of manufactureVSDuration of action of moving object

Solution Approach 1:

The patent modifies the electrolyte composition parameters to enable low-cost battery chemistries (such as iron-based or zinc-based systems) to achieve long and ultralong duration energy storage. By adjusting ionic concentrations, pH levels, and additive types, the system extends operational duration beyond 8 hours while maintaining cost-effectiveness through the use of abundant, inexpensive materials

Inventive Principle:
Principle #35Parameter changes

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 proposed solution achieves enhanced Coulombic efficiency, improved energy storage capacity, and extended cycle life, making it suitable for long-duration and ultra-long-duration energy storage applications.

Implementation Method 1

the additive suspended in the gel and accumulable at the metal-containing active material of the first electrode

Methodology Applied
Scientific EffectAdsorption: Adsorption

Implementation Method 2

the gel including a polymer network and a liquid medium, the polymer network carried in the liquid medium

Methodology Applied
Scientific EffectGel structure: Gel

Implementation Method 3

the additive including an iron-binding ligand formable into a coordination complex with one or more dissolution products of the first electrode on discharge of the electrochemical cell

Methodology Applied
Scientific EffectCoordination complex formation: Chemical Bonding

Implementation Method 4

an alkaline electrolyte in ionic communication between the first electrode and the second electrode

Methodology Applied
Scientific EffectElectrochemical reactions: Redox Reactions

Data Source

PatentUS20250132387A1Mitigating passivation of metal electrodes
Publication Date: 2025.04.24 FORM ENERGY INC
  • US20250132387A1 patent drawing
  • US20250132387A1 patent drawing
  • US20250132387A1 patent drawing

AI summary

According to one aspect, an electrochemical cell may include a first electrode including a metal-containing active material, a second electrode, and an electrolyte in ionic communication between the first electrode and the second electrode, the electrolyte including a gel and an additive, the gel including a polymer network and a liquid medium, the polymer network carried in the liquid medium, the additive suspended in the gel and accumulable at the metal-containing active material of the first electrode.