Metal-Air Battery Multi-Surface Anode Design
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Solution Overview
Problem
Current metal-air batteries have limited discharge capacity and energy density due to restricted air supply and the weight of conductive supports, with only one surface available for electrode reaction.
Innovation Solution
The electrochemical cell design includes an anode assembly with opposite surfaces and a cathode having folded portions for ionic continuity, along with an active metal ion conducting membrane, allowing active metal ions to be transported through multiple surfaces and improving capacity density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional metal-air battery uses only one surface for electrode reaction, then the structure is simple, but the discharge capacity and energy density are limited
Solution Approach 1:
The patent transitions from a single-surface electrode reaction to a multi-surface configuration by folding the cathode and ion-conducting membrane. This dimensional change allows the anode to contact the ion-conducting membrane at multiple locations (first and second contact portions), enabling electrode reactions to occur on both the first and second surfaces of the anode, thereby doubling the effective reaction area and improving discharge capacity without proportionally increasing structural complexity
Solution Approach 2:
The cathode and ion-conducting membrane are divided into multiple functional segments: the first contact portion, second contact portion, and intermediate portion. This segmentation allows each portion to serve specific functions (ionic conduction, electrical contact, structural support) and enables the multi-surface electrode reaction configuration while maintaining manufacturing feasibility through modular assembly
2Quantity of substance
If conductive supports are used in metal-air batteries, then structural stability is maintained, but the weight increases reducing energy density
Solution Approach 1:
The patent extracts and eliminates the conductive support component from the battery structure. Instead of using a conductive support to hold the cathode and ion-conducting membrane, the invention uses a non-conductive porous substrate that provides structural support without requiring electrical conductivity. This removal of the conductive support reduces the overall weight of the battery while maintaining structural stability, thereby improving energy density
Solution Approach 2:
The non-conductive porous substrate performs multiple functions: it provides structural support for the cathode and ion-conducting membrane, allows air permeation to reach the cathode, and does not interfere with the electrochemical reactions. This multi-functional design replaces the need for separate conductive support structures, reducing weight while maintaining both structural and functional integrity
3Productivity
If air supply is restricted in conventional metal-air batteries, then the structure is simplified, but the discharge capacity is reduced
Solution Approach 1:
The patent employs a non-conductive porous substrate with controlled porosity to manage air supply. The porous structure allows air to permeate through the substrate and reach the cathode effectively, ensuring adequate oxygen supply for the electrochemical reactions. The porosity is optimized to balance air permeability with structural integrity, enabling improved discharge capacity without requiring complex air supply systems such as pumps or channels
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 design enhances discharge capacity and energy density by enabling active metal ion transport through multiple surfaces and reducing the need for conductive supports, resulting in improved performance compared to conventional metal-air batteries.
Implementation Method 1
an active metal ion conducting membrane that is disposed between the anode and the cathode
Implementation Method 2
a cathode for oxidizing/reducing oxygen from the air
Data Source
AI summary
An electrochemical cell including: an anode assembly having opposite surfaces; and a cathode having at least one folded portion and having ionic continuity with the opposite surfaces of the anode assembly, wherein the anode assembly includes an anode, and an active metal ion conducting membrane that is disposed between the anode and the cathode, wherein the active metal ion conducting membrane has at least one folded portion. Also an electrochemical cell, an electrochemical cell module including the electrochemical cell, and methods of manufacturing the same.