Gradient Multilayer Electrodes for Lithium Batteries
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Achieving both high energy density and power density in lithium batteries, especially for electric vehicle applications, has been challenging, often requiring undesirable tradeoffs.
Innovation Solution
The development of gradient multilayer structures for lithium batteries, where porosity or solid-state ionic conductive material gradients are created using energy-assisted spray deposition techniques, optimizing the active material distribution and porosity across layers to enhance lithium-ion conduction and interface impedance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform porosity is used in battery electrodes, then manufacturing is simple, but both high energy density and power density cannot be achieved simultaneously
Solution Approach 1:
The patent applies local quality by creating a porosity gradient where different regions of the electrode have different porosity values. The first portion of the electrode has a first porosity value optimized for one function (e.g., higher porosity for better ion transport), while the second portion has a second porosity value optimized for another function (e.g., lower porosity for higher active material density). This spatial variation in porosity allows the electrode to simultaneously achieve high energy density and high power density without requiring complex manufacturing process changes.
2Reliability
If porosity gradient is implemented in electrode, then energy density and power density are maximized, but manufacturing complexity increases
Solution Approach 1:
The patent implements parameter changes by systematically varying the porosity parameter across different portions of the electrode. By controlling the porosity value to transition from a first porosity value in the first portion to a second porosity value in the second portion, the electrode achieves optimized performance characteristics. This parameter variation enables the simultaneous maximization of energy density and power density while maintaining a manageable structural complexity through controlled gradients rather than abrupt transitions.
3Manufacturing precision
If spray deposition is used to form gradient layers, then manufacturing precision is improved, but manufacturing time increases
Solution Approach 1:
The patent replaces traditional mechanical coating methods with spray deposition technology to form the gradient layers. Spray deposition enables precise control over layer porosity and composition by atomizing the coating material and controlling deposition parameters such as spray distance, angle, and material flow rate. This substitution of mechanical coating with spray-based deposition achieves superior manufacturing precision in controlling porosity gradients while maintaining reasonable manufacturing throughput.
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 approach maximizes both energy and power densities by optimizing the active surface area and interface contact, facilitating efficient lithium-ion conduction and reducing impedance, thereby addressing the traditional tradeoff challenges.
Implementation Method 1
the first layer is formed by energy-assisted spray deposition. In an aspect, the energy-assisted spray deposition comprises thermal spray deposition
Implementation Method 2
the energy-assisted spray deposition comprises cold spray deposition
Implementation Method 3
the second layer comprising an active material and a second amount of solid-state ionic conductive material... facilitating efficient lithium-ion conduction
Data Source
AI summary
A gradient multilayer structure for lithium batteries, a method for manufacturing thereof, and a lithium batteries comprise gradient multilayer structures. The multilayer structure has a porosity gradient with respect to adjacent layers of the multilayer structure or a solid-state ionic conductive material gradient with respect to adjacent layers of the multilayer structure.