Graded Alloy Lithium Anode Layer for Dendrite Suppression

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Solution Overview

Problem

Rechargeable lithium-ion batteries face issues with lithium dendrite formation and adverse reactions during charging and discharging cycles, leading to reduced operable battery lifetime and performance due to non-conducting materials and inhomogeneous alloy compositions.

Innovation Solution

An electrode with a graded metal alloy layer comprising a mixture of lithium and a further metal composition, where the concentration of lithium decreases away from the anode metal layer, providing a passivation or seed layer to mitigate volume and surface changes, inhibit dendrite formation, and protect the anode from adverse reactions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single overall composition alloy layer is used to inhibit lithium dendrite growth, then dendrite formation is suppressed, but electrical efficiency decreases due to large amounts of non-Li-conducting material

Engineering Contradiction:
Improvedendrite suppressionVSAvoidelectrical efficiency
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The patent applies local quality by creating a graded alloy layer where the composition varies spatially. The layer transitions from a Li-rich region adjacent to the Li metal layer (providing dendrite suppression) to a Li-poor region at the outer surface (minimizing dead weight). This gradient structure allows different regions to fulfill different functions optimally, resolving the contradiction between dendrite inhibition and electrical efficiency.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent employs parameter changes by systematically varying the lithium concentration parameter across the alloy layer thickness. The lithium content decreases gradually from the interface with the Li metal layer toward the outer surface, creating a continuous gradient. This parameter variation enables the layer to provide dendrite suppression where needed while minimizing the amount of non-conducting material, thus improving overall electrical efficiency.

Inventive Principle:
Principle #35Parameter changes

2Quantity of substance

If multi-element alloy anodes with different metal ratios are used, then Li holding capacity improves, but composition homogeneity decreases and dead weight increases

Engineering Contradiction:
ImproveLi holding capacityVSAvoidcomposition homogeneity
Core Design Contradiction:
Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The patent uses local quality by designing a composition gradient where the alloy composition is not uniform throughout. The Li-rich region provides high Li holding capacity, while the Li-poor region reduces dead weight. This spatial variation in composition allows the anode to achieve both high Li capacity and reduced inactive material, resolving the contradiction between quantity and homogeneity.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The alloy layer is effectively segmented into regions with different compositions. The gradient structure creates distinct zones: a Li-rich zone near the Li metal layer for capacity, and a Li-poor zone at the surface for efficiency. This segmentation allows each region to contribute differently to the overall performance, achieving both high Li holding capacity and reduced dead weight.

Inventive Principle:
Principle #1Segmentation

3Stability of the object's composition

If alloy material is used to suppress volume expansion, then mechanical stability improves, but electrical efficiency decreases due to non-conducting material

Engineering Contradiction:
Improvevolume stabilityVSAvoidelectrical efficiency
Core Design Contradiction:
Stability of the object's compositionVSLoss of energy

Solution Approach 1:

The patent applies parameter changes by creating a gradient in lithium concentration that transitions from high Li content near the Li metal layer to low Li content at the outer surface. This gradual parameter variation allows the structure to maintain volume stability through alloying while minimizing the amount of non-conducting material, thus preserving electrical efficiency. The gradient ensures that only the necessary amount of alloy material is used for volume stabilization.

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 graded alloy layer enhances battery performance and safety by reducing inactive material, promoting homogeneous anode metal stripping, and preventing dendrite formation, thereby increasing durability and energy density.

Implementation Method 1

the alloy compositions are not homogeneous over any horizontal subplane parallel to the substrate. Consequently, in a vertical direction the composition at every localized spot is different and made up by a comparatively large amount of non-or not optimally Li-conducting material

Methodology Applied
Scientific EffectAlloying expansion: Thermal Expansion

Implementation Method 2

the concentration of lithium (battery active metal) relative to the further metal composition decreases in a direction away from an interface with the anode metal layer

Methodology Applied
Scientific EffectDiffusion: Diffusion

Data Source

PatentUS20250336976A1Electrode with graded alloy layer, battery and method
Publication Date: 2025.10.30 LIONVOLT BV
  • US20250336976A1 patent drawing
  • US20250336976A1 patent drawing
  • US20250336976A1 patent drawing

AI summary

The present disclosure relates to an electrode (1) for a secondary lithium metal battery, the electrode comprises: a current collector (2), an anode metal layer (3) comprising lithium, and at least one graded metal alloy layer (4a,4b) that extends along one or more opposing faces of the anode metal layer. The graded metal alloy layer comprising a mixture of lithium and a further metal composition, whereby the concentration of lithium relative to the further metal composition decreases outwardly from the anode metal layer. The disclosure further relates to a battery comprising the electrode and a method of manufacturing.