Perforated Mesh Battery Electrode for Interlayer Contact
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Solution Overview
Problem
Conventional electrode manufacturing methods involve depositing electrode materials on isolated sides of a solid metallic sheet, limiting physical contact and potentially reducing the efficiency of electrochemical reactions in batteries.
Innovation Solution
A battery electrode structure featuring a middle layer of electrically conductive perforated mesh with top and bottom layers of electrode material in physical contact through perforations, allowing for improved electrical conductivity and reaction efficiency, with the mesh made from materials like steel, stainless steel, copper, or titanium, and the electrode material being a cured thixotropic slurry or paste containing graphite, silicon, or transition metal oxides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid metallic sheet is used as the middle layer, then structural strength is improved, but physical contact between electrode layers is limited
Solution Approach 1:
The patent applies a perforated mesh structure instead of a solid metallic sheet. The mesh contains multiple perforations that allow direct physical contact between the top and bottom electrode layers while maintaining structural strength. This porous configuration enables ionic and electronic transport pathways while preserving mechanical integrity of the electrode assembly.
2Ease of manufacture
If electrode material is deposited on isolated sides of a solid sheet, then manufacturing simplicity is improved, but electrochemical reaction efficiency deteriorates
Solution Approach 1:
The perforated mesh structure creates multiple contact points between electrode layers, significantly increasing the effective reaction area. This allows electrochemical reactions to occur at numerous locations simultaneously, improving overall reaction efficiency while maintaining a relatively simple manufacturing process of depositing material on both sides of the mesh.
Solution Approach 2:
The invention transitions from a two-dimensional isolated contact model to a three-dimensional interconnected contact model. The perforations create vertical pathways that enable direct contact between layers, adding a dimensional aspect that enhances reaction efficiency without complicating the manufacturing approach.
3Reliability
If a perforated mesh structure is used, then physical contact between electrode layers is improved, but device complexity increases
Solution Approach 1:
The solid metallic sheet is segmented into a mesh structure with multiple perforations. This segmentation creates multiple discrete contact points that collectively improve physical contact between layers. The segmented approach distributes the contact function across many small elements rather than requiring a single complex contact mechanism.
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
Enhances the efficiency of electrochemical reactions by ensuring physical contact between electrode layers, improving the conductivity and performance of battery electrodes, and allowing for flexible manufacturing processes including various mesh configurations and curing methods.
Implementation Method 1
curing the top and bottom layers of electrode material using one or more of heat, electromagnetic radiation and convection
Implementation Method 2
the electrode material may be a cured initially thixotropic slurry or paste
Data Source
AI summary
An electrode structure for a battery includes a middle layer made of an electrically conductive perforated mesh having a top surface, a bottom surface, a plurality of interconnected electrically conductive segments and a plurality of perforations among adjacent ones of the interconnected segments. A top layer of an electrode material is disposed on the top surface, and a bottom layer of the electrode material is disposed on the bottom surface, such that the top and bottom layers are disposed in physical contact with each other through the perforations in the middle layer. A method of manufacturing the electrode structure includes providing the layer of perforated mesh, applying the top and bottom layers of electrode material to the top and bottom surfaces, and curing the top and bottom layers of electrode material using one or more of heat, electromagnetic radiation and convection to produce a layer of cured electrode structure.