Honeycomb Battery Electrode Structure Without Current Collectors
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Solution Overview
Problem
Conventional battery technologies rely on current collectors, which increase costs and complicate resource recycling, as they require additional steps for separating noble metals and reduce the filling factor of electrode active materials.
Innovation Solution
A battery design featuring a honeycomb core negative electrode without a current collector, where the positive electrode is inserted into the hollow cells of the honeycomb core, enhancing the facing area and allowing for reduced or eliminated current collectors, and a separator with distinct insulation layers to facilitate current collection and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a current-collecting foil is used to support the electrode composite material layer, then the structural integrity and electrical conductivity are ensured, but the filling factor of electrode active material decreases and production cost increases
Solution Approach 1:
The patent removes the current-collecting foil from the battery structure entirely. The electrode active material is directly applied to the separator without requiring a separate current collector substrate, thereby eliminating the complexity and cost associated with current collectors while maximizing the filling factor of active material.
Solution Approach 2:
The separator serves multiple functions: it provides electrical insulation between electrodes, supports the electrode active material, and acts as the substrate for applying the paste. This multi-functionality eliminates the need for a separate current collector while maintaining structural integrity.
2Ease of manufacture
If a current-collecting foil is used to support the electrode composite material layer, then the electrode structure is stabilized, but resource recycling becomes more difficult and costly
Solution Approach 1:
By removing the current collector component entirely, the patent simplifies the recycling process. The electrode active material can be directly recovered from the separator without requiring additional separation steps to remove metal foils, thereby improving resource recycling efficiency and reducing process complexity.
3Quantity of substance
If the electrode active material is applied directly without current collector, then the filling factor increases, but the electrical conductivity and structural stability may be compromised
Solution Approach 1:
The separator is designed to perform multiple functions including providing electrical insulation, supporting the electrode structure, and enabling electrical contact. This multi-functional approach maintains reliability while allowing direct application of active material without current collector.
Solution Approach 2:
The patent modifies the properties of the separator and paste application process to ensure adequate electrical conductivity and structural stability. By optimizing parameters such as paste composition, application method, and separator properties, the system achieves reliable performance without requiring a current collector.
Data Source
AI summary
A battery includes a positive electrode, a negative electrode, and a separator. The negative electrode forms a honeycomb core. The honeycomb core includes a first face, a second face, a partition, and a circumferential wall. The second face faces the first face. The partition is formed between the first face and the second face. The partition extends in a grid pattern to separate a plurality of hollow cells. The circumferential wall surrounds a circumference of the partition. The separator includes a first layer and a second layer. The first layer covers at least part of the partition. The second layer covers at least part of the first face and the second face. The positive electrode includes a first region and a second region. The first region is inserted in the hollow cells. The second region extends outwardly beyond the second layer of the separator.