Graphene Foam-Protected Phosphorus Anode for Battery Volume Expansion

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Solution Overview

Problem

Current lithium-ion and sodium-ion batteries face limitations due to the poor performance of phosphorus-based anode materials, including low first-cycle efficiency, rapid capacity decay, and poor electrode integrity, primarily attributed to poor electronic conductivity and large volume expansion during cycling, which hinder their widespread adoption in energy storage applications.

Innovation Solution

The development of a graphene foam-protected phosphorus anode layer with a robust 3D network of electron-conducting pathways, where phosphorus material is lodged in the pores or as a thin coating on the pore walls of a solid graphene foam, preventing direct contact with the electrolyte and accommodating volume expansion, thereby enhancing conductivity and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If phosphorus material is used as anode active material to increase specific capacity, then lithium storage capacity is improved, but electronic conductivity deteriorates

Engineering Contradiction:
Improvelithium storage capacityVSAvoidelectronic conductivity
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The patent creates a composite structure where phosphorus particles are encapsulated within a three-dimensional graphene network. The graphene component provides excellent electronic conductivity (10^3-10^4 S/m) while the phosphorus core maintains high lithium storage capacity (2500 mAh/g). This composite architecture allows the conductive graphene matrix to compensate for the poor intrinsic conductivity of phosphorus, enabling both high capacity and good electrical performance to coexist.

Inventive Principle:
Principle #40Composite materials

2Quantity of substance

If phosphorus material is used to increase lithium storage capacity, then volumetric energy density is improved, but volume expansion during cycling worsens

Engineering Contradiction:
Improvevolumetric energy densityVSAvoidvolume expansion
Core Design Contradiction:
Quantity of substanceVSStability of the object's composition

Solution Approach 1:

The patent employs a three-dimensional graphene network as a flexible encapsulating structure that surrounds phosphorus particles. This graphene shell acts as a buffer that can elastically deform to accommodate the approximately 100% volume expansion of phosphorus during lithium insertion, while maintaining structural integrity. The flexible graphene framework prevents particle fragmentation and electrode delamination, allowing the high-capacity phosphorus material to undergo repeated expansion-contraction cycles without degradation.

Inventive Principle:
Principle #30Flexible shells and thin films

3Quantity of substance

If phosphorus material is used to improve lithium storage capacity, then first-cycle efficiency deteriorates, but capacity decay accelerates

Engineering Contradiction:
Improvelithium storage capacityVSAvoidfirst-cycle efficiency
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The patent introduces a conductive graphene layer as an intermediary between the phosphorus particles and the electrolyte. This graphene interface serves multiple functions: it facilitates efficient electron transfer to improve first-cycle efficiency, prevents direct contact between phosphorus and electrolyte that would cause harmful side reactions, and maintains stable electrical contact during volume changes. The graphene mediator thus improves both the initial efficiency and long-term stability of the phosphorus-based anode.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 configuration significantly improves reversible capacity, first-cycle efficiency, and long-term cycling stability, enabling high-rate capacity and compatibility with common electrolytes, while reducing internal pressure and electrolyte consumption, thus extending the battery's lifespan.

Implementation Method 1

large volume expansion (about 100%) during cycling

Methodology Applied
Scientific EffectVolume expansion: Thermal Expansion

Implementation Method 2

robust 3D network of electron-conducting pathways

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

phosphorus (P) has a Li storage capacity of 2500 mAh/g

Methodology Applied
Scientific EffectConversion reaction: Redox Reactions

Data Source

PatentUS11374216B2Graphene foam-protected phosphorus material for lithium-ion or sodium-ion batteries
Publication Date: 2022.06.28 HONEYCOMB BATTERY CO
  • US11374216B2 patent drawing
  • US11374216B2 patent drawing
  • US11374216B2 patent drawing

AI summary

A lithium- or sodium-ion battery anode layer, comprising a phosphorus material embedded in pores of a solid graphene foam composed of multiple pores and pore walls, wherein (a) the pore walls contain a pristine graphene or a non-pristine graphene material; (b) the phosphorus material contains particles or coating of P or MPy (M=transition metal and 1≤y≤4) and is in an amount from 20% to 99% by weight based on the total weight of the graphene foam and the phosphorus material combined, and (c) the multiple pores are lodged with particles or coating of the phosphorus material. Preferably, the solid graphene foam has a density from 0.01 to 1.7 g/cm3, a specific surface area from 50 to 2,000 m2/g, a thermal conductivity of at least 100 W/mK per unit of specific gravity, and/or an electrical conductivity no less than 1,000 S/cm per unit of specific gravity.