Lithium-ion Cell Multimodal Particle Packing Density
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Solution Overview
Problem
Lithium-ion cells face challenges in achieving high energy density while maintaining a compact form factor, as energy density decreases with thinner cell thickness, and existing technologies struggle to optimize electrode porosity and packing density effectively.
Innovation Solution
The use of active electrode particles with a multimodal particle size distribution (PSD) and a packing density greater than approximately 0.56, which allows for increased energy density by optimizing porosity and packing structure without increasing electrode thickness, achieved through a method involving the combination of particles with different size distributions and careful slurry mixing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If cell thickness is reduced to achieve compact form factor, then device size is decreased, but energy density is reduced
Solution Approach 1:
The patent changes the particle size distribution parameters of the electrode material, using a multimodal distribution with specific D10, D50, and D90 values to optimize packing density and energy density while maintaining thin cell geometry
Solution Approach 2:
The patent employs a composite particle size distribution combining fine particles (D10: 3-7 μm), medium particles (D50: 8-12 μm), and coarse particles (D90: 15-25 μm) to create an optimized packing structure that maximizes energy density in thin cells
2Reliability
If electrode porosity is increased to improve ion transport, then ion conductivity is enhanced, but packing density is reduced
Solution Approach 1:
The patent applies local quality by creating different particle size regions within the electrode structure, where finer particles fill voids in coarser particle regions, optimizing both local porosity for ion transport and overall packing density
Solution Approach 2:
The patent implements a nested particle structure where smaller particles (D10) are embedded within the interstices of medium particles (D50), which are themselves positioned among coarse particles (D90), creating a hierarchical packing that maximizes density while maintaining transport pathways
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 enhances energy density while maintaining a compact form factor, mitigating reductions in energy density associated with thinner cell designs and achieving a packing density beyond random close packing limits, thereby enabling thinner devices with suitable energy capacity.
Implementation Method 1
packed active electrode particles that include a multimodal particle size distribution (PSD) and a packing density, for example, greater than approximately 0.56
Data Source
AI summary
A lithium-ion cell can include at least one electrode that includes packed active electrode particles that include a multimodal particle size distribution (PSD) and a packing density, for example, greater than approximately 0.56. Various other apparatuses, systems, methods, etc., are also disclosed.