3D Microstructured Electrode Pillars for Energy Storage
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Solution Overview
Problem
Conventional energy storage devices, such as batteries, face challenges in achieving high energy density and efficient active material utilization due to limitations in current collection methods and the volume expansion issues with materials like silicon anodes, leading to reduced capacity and performance over charge/discharge cycles.
Innovation Solution
The development of three-dimensional structures with microstructured anodically active material layers on a backbone structure, featuring a void fraction to accommodate volume changes, which allows for increased surface area and efficient electron and ion transfer between anode and cathode, enhancing energy storage and retrieval capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If three-dimensional structures with microstructured anodically active material layers are used, then energy storage per unit geometrical area and energy retrieval speed are improved, but device complexity increases
Solution Approach 1:
The patent transitions from conventional two-dimensional laminar electrode architectures to three-dimensional structures with vertical pillars and microstructured anodically active material layers. This dimensional change increases the surface area and active material volume within the same geometrical footprint, thereby improving energy storage capacity and retrieval speed without proportionally increasing the device's external dimensions.
Solution Approach 2:
The patent implements a nested structure where microstructured anodically active material layers are positioned on lateral surfaces of vertical pillars, which themselves are nested within the overall electrode assembly. The void spaces between pillars are utilized to accommodate separator layers and electrolyte, creating a space-efficient nested arrangement that maximizes energy density while managing structural complexity.
2Quantity of substance
If high capacity materials like silicon anodes are used, then energy density is improved, but volume expansion during cycling causes disintegration and capacity loss
Solution Approach 1:
The patent employs microstructured anodically active material layers with controlled porosity and void fraction (at least 0.1). This porous structure provides internal space to accommodate the volume expansion of high capacity materials like silicon during lithium insertion, preventing disintegration and exfoliation. The porous architecture maintains structural integrity while allowing the active material to undergo repeated expansion and contraction cycles.
Solution Approach 2:
The patent applies different structural characteristics to different regions of the electrode. The anodically active material layers are specifically engineered with microstructured porosity and void spaces in the regions where volume expansion occurs, while maintaining appropriate density and composition in other areas. This localized structural optimization allows high capacity materials to function reliably without compromising overall electrode performance.
3Device complexity
If conventional two-dimensional laminar architectures are used, then device simplicity is maintained, but surface area and active material utilization are limited
Solution Approach 1:
The patent introduces vertical dimensionality with pillars extending in the z-direction, creating three-dimensional electrode structures. This allows the electrode surface area to extend vertically rather than only horizontally, significantly increasing the available surface area for electrochemical reactions within the same device footprint. The vertical arrangement of active material layers on pillar surfaces provides accessible surface area without requiring proportionally larger device dimensions.
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
These structures enable higher energy storage per unit geometrical area and faster energy retrieval compared to two-dimensional devices, making them suitable for miniaturization and applications with high energy density requirements.
Implementation Method 1
the layer containing a void fraction that accommodates significant volume changes in the anodically active material as it cycles between a charged and a discharged state
Implementation Method 2
carrier ions, such as lithium, sodium or potassium ions, move between an anode electrode and a cathode electrode through an electrolyte
Implementation Method 3
The anode and cathode current collectors pool electric current from the respective active electrochemical electrodes and enables transfer of the current to the environment outside the battery
Data Source
AI summary
A structure for use in an energy storage device, the structure comprising a backbone system extending generally perpendicularly from a reference plane, and a population of microstructured anodically active material layers supported by the lateral surfaces of the backbones, each of the microstructured anodically active material layers having a void volume fraction of at least 0.1 and a thickness of at least 1 micrometer.