Monolithic Carbon Electrode Cavities Without Metal Foil Collectors
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Solution Overview
Problem
Conventional lithium-ion battery electrodes face challenges in deformability, requiring metal foil current collectors for mechanical support, which limits their capacity, increases irreversible capacity, and complicates manufacturing, while also restricting the use of non-rollable electrode materials.
Innovation Solution
The development of self-supported, monolithic carbon electrodes with engineered cavities and a conductive carbon matrix that eliminates the need for metal foil current collectors, utilizing pyrolyzed carbonized polymers as both active material and current collector, and incorporating silicon for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal foil current collectors are used to provide mechanical support to electrode materials, then the electrode structure maintains sufficient deformability for rolling, but the battery capacity is limited and irreversible capacity increases
Solution Approach 1:
The patent merges the current collector function and active material function into a single carbon-based structure. The carbon material serves dual purposes: providing mechanical support (replacing metal foil current collectors) and contributing to battery capacity through lithium insertion/extraction reactions. This eliminates the need for separate metal foil components and increases the proportion of active material in the electrode.
Solution Approach 2:
The carbon-based electrode structure performs multiple functions simultaneously: it provides mechanical support, conducts electricity, stores lithium ions, and protects against overcharge/discharge. This multi-functionality eliminates the need for separate metal foil current collectors and reduces irreversible capacity associated with metal foil materials.
2Strength
If metal foil current collectors are used for mechanical support, then the electrode maintains structural integrity, but the manufacturing process becomes more complex
Solution Approach 1:
The patent combines multiple manufacturing steps into a simpler process by eliminating the need to separately attach metal foil current collectors to active materials. The carbon-based structure is formed directly as a self-supported electrode, reducing the number of assembly steps and simplifying manufacturing.
3Shape
If conventional electrode materials are used, then the electrode can be formed into sheets, but non-rollable materials cannot be utilized
Solution Approach 1:
The patent changes the physical and chemical parameters of the electrode material to carbon-based materials with appropriate mechanical properties. This allows the use of diverse materials that would otherwise be non-rollable, as the carbon matrix provides the necessary mechanical support while enabling lithium insertion/extraction reactions.
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 electrodes offer higher capacity, improved overcharge/discharge protection, reduced irreversible capacity, potential cost savings, and increased surface area per unit volume, enabling the use of non-rollable materials and simplifying manufacturing.
Implementation Method 1
utilizing pyrolyzed carbonized polymers as both active material and current collector
Implementation Method 2
a conductive carbon matrix that eliminates the need for metal foil current collectors
Implementation Method 3
The first electrode may be an electrode as described herein... a second electrode located within the plurality of pores, wherein the separator electrically isolates the first electrode from the second electrode. The battery may be a lithium ion battery and/or the second electrode may be a lithiated intercalation compound
Data Source
AI summary
In certain embodiments, an electrode includes a body of material formed in substantial part of carbon, the body having an exterior surface and an interior located within the exterior surface, and a plurality cavities located in the interior of the body. Each of the cavities is in communication with the exterior of the body and has an interior surface. The cavities can each be sized to accommodate a battery separator located therein and substantially covering the interior surface of the cavity.